2010 Emerge Service Manual

2

INTRODUCTION

This Maintenance Manual is compiled by TOMBERLIN Company for dealers authorized by

the Company and their technicians. The Manual is only for the maintenance and repair of

electric vehicles of E-MERGE series.

TOMBERLIN reserves the rights to revise the specifications and design from time to time

and the electric vehicles and other products. are subject to improvement that may influence

the maintenance procedure with no notice, nor obligation to alternate devices sold

previously.

Before starting any service on the electric vehicle, read the Manual carefully and note the

difference of the following symbols:

This indicates Note! Alarm! Watch your safety!

WARNING The symbol indicates a danger may occur, calling the attentions of

the driver, passenger, by stander or inspection and maintenance

personnel.

CAUTION It describes some special precautions to avoid vehicle damage.

3

Chapter 1 Overview

Safety Precautions ................................................................................................................................1-1

Preparation for Emergency ............................................................................................................1-1

Safe Use of Lubricating Oil.............................................................................................................1-1

Safe Use of Battery ........................................................................................................................1-1

Protection of Vehicle Safety ...........................................................................................................1-2

Electrical Safety During Maintenance.............................................................................................1-2

Use the Designated Lifting Jack.....................................................................................................1-5

Use Appropriate Tools...........................................................................................................................1-6

Special Tools ..................................................................................................................................1-6

Instrumentation for Electric Control System ...................................................................................1-6

Cautions ................................................................................................................................................1-6

Washing and Cleaning ...................................................................................................................1-6

Keep Tidy .......................................................................................................................................1-6

Tightening Torque...........................................................................................................................1-7

Parts Replacement.........................................................................................................................1-7

Washer, Grease Fitting and O-ring.................................................................................................1-7

Bearing and Oil Seal ......................................................................................................................1-7

Recommendations on Disassembly and Assembly........................................................................1-7

Chapter 2 Regular Inspection and Adjustment

Regular Maintenance ............................................................................................................................2-1

Periodic Lubrication Plan.......................................................................................................................2-2

Braking System..................................................................................................................................2-4

Braking Inspection .............................................................................................................................2-4

Inspection of Parking Brake ...............................................................................................................2-5

Inspection of Brake Drum and Brake Shoe........................................................................................2-6

Inspection of the Accelerator Pedal ...................................................................................................2-9

Inspection of the Steering System .....................................................................................................2-9

Inspection of the Steering Linkage................................................................................................... 2-10

Inspection of Stub Axle .................................................................................................................... 2-11

Inspection of the Front Wheel Alignment ......................................................................................... 2-11

Install for the Adjustment of Toe-in: ................................................................................................. 2-12

Inspection of Tires and Wheel Rim .................................................................................................. 2-12

Inspection of the Front Wheel Bearing............................................................................................. 2-13

Inspection of the Rear Axle Bearing ................................................................................................ 2-13

Inspection of the Shock Damper...................................................................................................... 2-14

Inspection of the Seat Belt ............................................................................................................... 2-14

Chapter 3 Canopy

Removal of the Canopy.........................................................................................................................3-1

Remove..........................................................................................................................................3-1

Install..............................................................................................................................................3-1

4

Removal of Canopy Rods......................................................................................................................3-1

Remove..........................................................................................................................................3-1

Install..............................................................................................................................................3-2

Removal of the Pillar .............................................................................................................................3-2

Remove..........................................................................................................................................3-2

Install..............................................................................................................................................3-3

Chapter 4 Body

Removal of the Front Bumper ...............................................................................................................4-1

Remove..........................................................................................................................................4-1

Removal of the Rear Tray................................................................................................................4-1

Remove..........................................................................................................................................4-1

Removal of the Rear Bumper .........................................................................................................4-1

Remove..........................................................................................................................................4-1

Install..............................................................................................................................................4-1

Removal of the Seat Cushion................................................................................................................4-2

Remove..........................................................................................................................................4-2

Install..............................................................................................................................................4-3

Removal of Front Cover ........................................................................................................................4-4

Remove..........................................................................................................................................4-4

Install..............................................................................................................................................4-4

Removal of the Dashboard....................................................................................................................4-4

Remove..........................................................................................................................................4-4

Install..............................................................................................................................................4-5

Removal of the Rear Cover ...................................................................................................................4-6

Remove..........................................................................................................................................4-6

Install..............................................................................................................................................4-6

Rear cover.............................................................................................................................................4-9

Chapter 5 Front Axle

Front axle ..............................................................................................................................................5-1

Removal of the Front Axle .....................................................................................................................5-2

Remove .............................................................................................................................................5-2

Inspect ...............................................................................................................................................5-6

Install .................................................................................................................................................5-7

Chapter 6 Driving Axle

Driving axle............................................................................................................................................6-1

Removal of the Driving Axle ..................................................................................................................6-2

Remove..........................................................................................................................................6-2

Inspect and test ..............................................................................................................................6-5

Install..............................................................................................................................................6-6

Gearbox.................................................................................................................................................6-8

Removal of the Differential Gear ...........................................................................................................6-9

Remove..........................................................................................................................................6-9

5

Inspection..................................................................................................................................... 6-11

Install............................................................................................................................................ 6-12

Chapter 7 Brake System

Brake System........................................................................................................................................7-1

Brake Pedal...........................................................................................................................................7-2

Parking brake handle ............................................................................................................................7-3

Accelerator pedal ..................................................................................................................................7-4

Chapter 8 Steering System

Steering System ....................................................................................................................................8-1

Removal of the Steering System ....................................................................................................8-2

Removal of the Steering Gear ........................................................................................................8-3

Disassembly of the Steering Gear..................................................................................................8-4

Install..............................................................................................................................................8-7

Chapter 9 Electric Component

Key switch removal ........................................................................................................................9-1

Key switch installation ....................................................................................................................9-1

Removal of forward/reverse gear switch ........................................................................................9-1

Installation of forward/reverse gear switch .....................................................................................9-2

Battery discharge meter removal ...................................................................................................9-2

Battery discharge meter installation ...............................................................................................9-3

Horn removal..................................................................................................................................9-3

Horn installation .............................................................................................................................9-3

Combination switch removal ..........................................................................................................9-4

Combination switch installation ......................................................................................................9-4

Controller removal ..........................................................................................................................9-5

Controller installation......................................................................................................................9-6

Charger receptacle removal ...........................................................................................................9-7

Charger receptacle installation.......................................................................................................9-7

Battery removal ..............................................................................................................................9-7

Battery installation..........................................................................................................................9-8

DC converter removal ....................................................................................................................9-8

DC converter installation ................................................................................................................9-8

Removal of DC changeover contactor and diode assembly...........................................................9-9

Installation of DC changeover contactor and diode assembly...................................................... 9-10

Motor removal .............................................................................................................................. 9-10

Motor installation .......................................................................................................................... 9-12

Removal of bulb of headlight and front turn signal light................................................................ 9-12

Headlight installation .................................................................................................................... 9-13

Tail light removal .......................................................................................................................... 9-13

6

Tail light installation...................................................................................................................... 9-14

High mount stop lamp removal..................................................................................................... 9-14

High mount stop lamp disassembly.............................................................................................. 9-14

High mount stop lamp installation ................................................................................................ 9-14

Wiper removal .............................................................................................................................. 9-15

Chapter 10 Troubleshooting

Troubleshooting Instructions Part 1..................................................................................................... 10-1

Check procedures ........................................................................................................................ 10-3

Index for check procedures .......................................................................................................... 10-3

Check Procedure 1-- Battery/ voltage check ................................................................................10-4

Check Procedure 2--Accelerator signal voltage ...........................................................................10-4

Check Procedure 3-- Motor voltage at A1 and A2........................................................................ 10-4

Check Procedure 4 - TOW/RUN switch ....................................................................................... 10-5

Check Procedure 5—Battery voltage ........................................................................................... 10-5

Check Procedure 6—Circuit check for key switch and accelerator pedal switch.......................... 10-5

Check Procedure 7--Controller signal 10-7

Check Procedure 7A—Pin 1 10-7

Check Procedure 7B—Pin 4 and 5 10-8

Check Procedure 7C—Pin 7 10-9

Check Procedure 7D—Pin 6 10-9

Check Procedure 7E—Pin 3 10-9

Check Procedure 8 – voltage at the red wire jack of charger receptacle.................................... 10-10

Check Procedure 9—Motor speed sensor ................................................................................. 10-10

Check Procedure 10—forward/reverse gear switch ................................................................... 10-11

Check Procedure 11—Reverse buzzer ...................................................................................... 10-11

Check Procedure 12 -- Battery discharge meter ........................................................................ 10-12

Check Procedure 13-- High mount stop lamp ............................................................................ 10-12

Check Procedure 14 - wiper....................................................................................................... 10-13

Check Procedure 15—flashing light ........................................................................................... 10-13

Troubleshooting Instructions Part 2............................................................................................10-14

CHAPTER 11 BATTERY AND CHARGER

Battery ................................................................................................................................................. 11-1

Overview ...................................................................................................................................... 11-1

Common misconceptions about battery ....................................................................................... 11-2

Battery replacement ..................................................................................................................... 11-3

Battery maintenance .................................................................................................................... 11-4

Preventative maintenance............................................................................................................ 11-4

Self discharge .............................................................................................................................. 11-5

Electrolyte liquid level................................................................................................................... 11-5

Mineral content............................................................................................................................. 11-6

Vibration damage ......................................................................................................................... 11-6

7

Battery charging ........................................................................................................................... 11-6

Deep discharge ............................................................................................................................ 11-7

Premature excessive discharge ................................................................................................... 11-7

AC power supply line.................................................................................................................... 11-7

Alternating use of vehicles ........................................................................................................... 11-7

Electric vehicle and charger numbering ....................................................................................... 11-8

Battery troubleshooting diagram .................................................................................................. 11-9

Inspection and test of the battery ............................................................................................... 11-10

Inspection and test of the battery charger .................................................................................. 11-10

Charging voltage inspection ....................................................................................................... 11-10

Inspection with hydrometer ........................................................................................................ 11-10

Procedures for inspection with hydrometer ................................................................................ 11-11

Calibration of hydrometer ........................................................................................................... 11-11

Hydrometer inspection result presentation ................................................................................. 11-11

Discharge test ............................................................................................................................ 11-12

Procedures for discharge test .................................................................................................... 11-13

Discharge test result presentation.............................................................................................. 11-13

Battery troubleshooting example................................................................................................ 11-14

Battery storage........................................................................................................................... 11-15

Battery charge 11-16

Overview .................................................................................................................................... 11-16

Conditions to be noted before charging...................................................................................... 11-16

Get to know the charger ............................................................................................................. 11-17

Removal of the charger .............................................................................................................. 11-18

Maintenance of the battery charger............................................................................................ 11-19

Troubleshooting ......................................................................................................................... 11-19

Diode test procedure .................................................................................................................. 11-20

Procedures for component replacement .................................................................................... 11-20

Charger trouble-shooting procedure........................................................................................... 11-20

On-board charger 11-23

Operating Instructions 11-23

Maintenance instructions 11-24

Specifications 11-24

Installation Instructions 11-25

Chapter 12 Electric Motor

Overview ............................................................................................................................................. 12-1

Exterior inspection of the electric motor .............................................................................................. 12-1

Check Procedure 1 internal short circuit ........................................................................................... 12-1

Check Procedure 2 disconnection of armature circuit.......................................................................12-1

Check Procedure 3 open excitation circuit........................................................................................ 12-2

Removal of the electric motor.............................................................................................................. 12-3

Inspection and test of the motor element ............................................................................................ 12-4

Inspection of the armature............................................................................................................ 12-4

Armature earth test....................................................................................................................... 12-4

8

Inspection of the excitation winding.............................................................................................. 12-5

Motor element .............................................................................................................................. 12-5

Bearing inspection........................................................................................................................ 12-6

Removal of the bearing ................................................................................................................ 12-6

Mounting of the bearing................................................................................................................ 12-6

Inspection of the speed sensor magnet........................................................................................ 12-6

Removal of the speed sensor magnet.......................................................................................... 12-7

Mounting of the speed sensor magnet ......................................................................................... 12-7

Readjustment of the electric motor............................................................................................... 12-7

Specifications for the electric motor..................................................................................................... 12-8

Assembly of the electric motor ............................................................................................................ 12-9

Mounting of the electric motor ........................................................................................................... 12-11

Speed sensor of the electric motor.................................................................................................... 12-14

Inspection of the speed sensor of the electric motor .................................................................. 12-14

Removal of the speed sensor..................................................................................................... 12-14

Mounting of the speed sensor of electric motor.......................................................................... 12-14

Overview

MERGE 1-1

Chapter 1

Safety Precautions

WARNING

During the maintenance of these vehicles, the following safety precautions can be taken to prevent

serious accidents.

Preparation for an Emergency

To prevent a potential injury or fire hazard, the following

simple articles should be prepared. For example:

• First-aid kit

• Fire extinguisher

• Emergency phone

Safe Use of Lubricating Oil

While refilling or replacing oil, do not smoke and keep

away from fire.

Any spilled grease should cleaned on a regular basis

and be handled properly.

Safe Use of Battery

Before maintenance, the battery acid should be sealed.

The battery can give off explosive gases. The battery

should be kept away from the ignition source. The liquid

level of electrolyte should be inspected with the use of

flashlight.

Do not measure and test the voltage after connecting the

battery wire. A voltmeter or hydrometer should be used

for taking this measurement.

Do not connect the wire with the negative electrode first.

Connect it at last.

Do not charge the battery while it is refrigerated. The

battery should be unfrozen before it is charged.

To prevent the production of explosive hydrogen gas, the

Overview

MERGE 1-2

Chapter 1

battery should be placed in an area with good ventilation

while charging.

The electrolyte of the battery contains sulfuric acid,

which is toxic and highly corrosive and should be

prevented from being spilled onto the skins, eyes and

clothes. In the event that electrolytes are spilled into

eyes, water should be used to clean the eyes for 15

minutes and effective medical treatment should be

taken.

WARNING

During the maintenance of these vehicles, the following

safety precautions can be adopted to prevent serious

accidents.

Vehicle Safety During Maintenance

• The parking brake should be applied.

• Blocks should be placed in front of the front tires.

• No one should be allowed to stand in front of or

behind the vehicle being serviced.

Electrical Safety During Maintenance

DANGER

• Battery contains explosive gas! Smoking is strictly

prohibited. Sparks and open flames should be kept

away from the electric vehicle and the working area.

The place where the battery is charged should be a

space where it is kept in good ventilation. While

maintaining or working beside the battery, the

operator should wear a full face mask and rubber

gloves.

• Batteries are toxic and contain acid fluid that may

cause serious burns if the fluid should contact the

skin. Anti-acid measures:

Overview

MERGE 1-3

Chapter 1

• Exterior: Flush the area where acid is spilled with

water, and visit the doctor immediately.

• Oral medication: Drink a large quantity of milk or

water before taking milk of magnesia or vegetable

oil. Visit the doctor immediately.

• Eyes: If battery acid should contact your eyes, you

should flush your eyes with water for 15 minutes

and immediately contact your doctor.

WARNING

• The electric vehicle can only be repaired or

maintained by technician with adequate training.

Even the personnel who are in charge of simple

repair or maintenance are required to have the

knowledge or experience in relation to electrical and

mechanical maintenance.

• Please follow the procedures contained in this

Manual, and note all the “DANGER”, “WARNING”

AND “NOTICE” marks contained in this Manual and

attached to the electric vehicle.

• Misuse of electric vehicles or inappropriate

maintenance may result in the performance

degradation of the vehicle or serious personal injury.

• Any refit or alteration of the electric vehicle that may

affect its stability or maneuverability or any speed

increase beyond the maximum speed specified in

the manufacturer’s specifications may result in

death and serious personal injury.

• Refer to the user’s manual for the corresponding

positions labeled on the electric vehicle of all

“WARNING” marks and ensure that they are in

place and easily visible.

• During the maintenance of electric vehicle, please

wear the safety goggles or effective eye-shields.

While maintaining or working beside the battery, the

operator should wear full face mask and rubber

gloves. During the maintenance of electric vehicle, it

is strictly prohibited to wear loose clothes or earrings,

watches, necklace and bracelets, etc.

Overview

MERGE 1-4

Chapter 1

• Moveable elements! It is strictly prohibited to

maintain the electric vehicle while it is in operation.

• Hot! It is strictly prohibited to maintain a hot motor.

Any violation of this warning may result in serious

burns.

• While working beside the battery or electrical

element, the operator should use insulated tools

with special care to avoid short circuit of the

component or wiring.

• Before servicing the electric vehicle, please turn the

key switch to the OFF position and take the key out.

Turn FWD/REV switch to NEUTRAL position and

chock the wheels with blocks.

Overview

MERGE 1-5

Chapter 1

• To avoid unintentional start-up of the electric

vehicle, please turn the Tow/Run switch to the

TOW position before disconnecting or

connecting the battery.

• After disconnection of the battery, please wait for 90

seconds to allow for the discharge of the capacitor

in the controller.

NOTICE:

After removing or replacing the wire, please arrange

and fix the wiring and wiring harness. Inappropriate

arrangement of the wiring and wiring harness may

result in the malfunction of the vehicle, property

damage and/or personal injury and death.

Use the Designated Lifting Jack

Front: put the lifting jack below the pivot to support it.

Rear: Use the portion of crossed frames.

Caution:

In the case that the lifting jack is placed behind the

vehicle, the lifting jack should be prevented from

touching the back tower bar.

First, remove the

positive electrode

cable

Disconnect the

storage battery

cable here

Overview

MERGE 1-6

Chapter 1

Use Appropriate Tools

To prevent the components and the vehicle from damage,

appropriate tools must be used.

Special Tools

The use of appropriate special tools is necessary for the

improvement of vehicles, accurate adjustment and

assembly. The use of appropriate special tools can

prevent damage resulting from the use of inappropriate

tools.

Instrumentation for Electric Control System

1. Pocket detector

This device is of vital importance to the inspection of

the electrical control system.

2. Hydrometer

This instrument is designed to measure the precise

specific grayte. of the electrolyte.

Cautions

Washing and Cleaning

Before the maintenance, thoroughly clean the body and

exterior of the components. During the cleaning, care

should be taken to protect electrical components such as

the relay and controller.

Keep Tidy

To ensure that vital parts are not misplaced, put them in a

secure location away from disarray.

Overview

MERGE 1-7

Chapter 1

Tightening Torque

Tighten the bolts, nuts or screws pursuant to the

instructions on the torque in each chapter.

Parts Replacement

We recommend that you use E-MERGE original parts for

all replaceable parts. Use the oil or grease

recommended by TOMBERLIN during the assembly,

inspection and repair.

Washer, Grease Fitting and O-ring

During the inspection and repair of vehicles, all the

washers, grease fittings and O-rings removed should be

cleaned up before being mounted.

Bearing and Oil Seal

During the mounting of bearing and oil seals on which

the manufacturer’s mark and number are present, the

mark and number should face outwards for easy

identification. All the bearing and oil seals, once removed,

must be replaced with new ones. To apply the oil seal,

cover a thin layer of light lithium grease over the oil seal.

While mounting the bearing, the lubricants should be

fully applied.

Recommendations on Disassembly and Assembly

Follow the following recommendations to remove and

mount the parts:

• Whenever the parts are disassembled, they must be

cleaned and air dried.

• Apply the lubricant oil over the surface of the parts that

are to be mounted.

• After the mounting of all parts in place, verify that all

movable parts are in normal operation.

Original

Regular Inspection and Adjustment

MERGE 2-1

Chapter 2

Regular Maintenance

Normal maintenance is of paramount importance to the optimal performance and safe operation of

vehicles.

B WARNING

Unless otherwise required, the master switch must be turned off and the parking brake must be

applied during the maintenance.

C–Check CA-Check and Adjustment R-Replacement S-Service CL-Cleaning and Lubricating

L-Lubricating

Remarks Before

operation

3100 miles5000

kilometers(Semiannuall

y)

6200 mile 10000

kilometers(Annually)

12400 miles 20000

kilometers(Every two

years)

18600 miles30000

kilometers(Every three

years)

Charging S S S S S

Clean the top of the

battery and inspect the

retaining screws and

terminals for tightness.

S S S S S

Inspect the brake pedal

for free travel and make

adjustments when

necessary.

C CA CA CA CA

Inspect the operation of

the steering wheel C C C C C

Inspect the tire pressure

and the tire recession

and tread for damage C CA CA CA CA

Inspect the body and

chassis for damage C C C C C

Inspect all the bolts, nuts

and screws for tightness C C C C C

Inspectio

n before

operatio

n

Inspect the reverse

buzzer for normal

operation C C C C C

Inspect the level of the

electrolyte C C C C Monthly

inspectio

nInspect all the connecting

lines C C C C


MERGE 2-2

Chapter 2

Clean/Lubricate the pedal

control area L L L L

Inspect all the insulated

wires for rupture or

dirtiness C C C C

Semian

nual

inspecti

onInspect the shock

damper for oil leakage

and damage of spring C C C C

Conduct discharging test S S S

Use terminal protective

agent S S S

Inspect the brake shoes

for tightness and the rear

axle bearing for normal

operation

C C C

Inspect the steering

knuckle bushing for

normal operation/Adjust

front wheel alignment

CA CA CA

Inspect the nuts of the

wheel for tightness and

the front-wheel bearing

for normal operation

C C C

Replace the lubricating

oil in the gear box R

Annual

inspecti

on

Inspect the parking pedal

for free travel and make

adjustments when

necessary.

CA CA CA

Inspect the rear axle

bearing and replace it if

abrasion is identified R

Inspectio

n every

three

yearsInspect for oil leakage,

and adjust the gear box

when necessary CA


MERGE 2-3

Chapter 2

Periodic Lubrication Plan

Periodic lubrication plan

Normal intervals Maintenance Lubricated

pointsRecommend lubricating oil

Brake pedal shaft 1 3# Lithium based grease

Parking brake 2 3# Lithium based grease

Accelerator pivot bar foot 3 3# Lithium based grease

Charger receptacle 4 NYE760G

Front suspension 5 3# Lithium based grease

Front stub axle 7 Lithium based grease

The user or trained

technician applies the

lubricating oil once a

quarter (every 50

working hours)

Braking grease cup 8 DOT3 3000 brake oil

Inspect the driving axle/oiled

cork position. 6

32.8 ounce 1.1 liter 37OZ

lubricating oil (GL - 5)

The trained

technician applies the

lubricating oil once a

year (every 100

working hours)

Inspect the front-wheel

bearing (Remount when

necessary).

7 3# Lithium based grease


MERGE 2-4

Chapter 2

Braking System

Main Brake Inspection

1. Remove:

· Anti-slip pedal

· Protective cover plate

Care should be taken to avoid scraping the body.

2. Inspect

· Brake master cylinder

· Brake Oil Pipeline

· Tee joint

· Front wheel brake caliper

Oil leakage !if any, replacement is required

· Front wheel brake shoe

Standard thickness

7.0 mm (0.28 in)

Maximum wear value of thickness:

2.5 mm (0.1 in)

· Brake disc

Standard thickness:

4.0 mm (0.16 in)

Maximum thickness wear value:

1.0 mm (0.04 in)

Damaged/defective one is to be replaced


MERGE 2-5

Chapter 2

3. Measure:

· Free play of the brake pedal

Push against the pedal by hand (slightly) and measure

the distance it travels before the pressure is lost.

Defects are to be replaced.

Free Travel of the brake pedal

13mm(0.512 in

Inspection of Parking Brake

1. Turn the key switch to "OFF" position and take out the

key.

2. Remove the protecting jacket of brake handle.

1. Inspect

· Parking brake ratchet

· Ratchet brake

Worn or damaged ones are to be replaced.

2. Measure:

· Free travel

15mm (0.591in)

In case of non-compliance with the standard,

adjustment is to be made.


MERGE 2-6

Chapter 2

Procedures for the Adjustment of Free Travel

· Loosen the locknut

· Adjust the free travel via adjusting nut

· Tighten the locknut

· Re-inspect the free travel

Inspection of Brake Drum and Brake Shoe

1. Turn the key switch to the "OFF" position and take

out the key.

2. Wedge the blocks onto the front lower part of the

front tires. Lift the rear body with the lifting jack.

3. Remove the rear tire lug nuts and then the rear

wheels.

4. Loosen the brake drum and knock slightly on the

drum with mallet.

5. Inspect

· Internal surface of the brake drum

Oil ! fully clean until no oil is found

Scrape ! Rub lightly with the abrasive cloth

· Brake wheel cylinder

Where the upstream assembly is in normal working

condition, step on the brake pedal. In case the brake

wheel cylinder cannot open the brake shoe or oil

leakage is found, the brake wheel cylinder is to be

replaced with a new one.


MERGE 2-7

Chapter 2

6. Measure

In case the inside diameter of the drum does not

meet the specification, it will be replaced with a new

one.

Standard inside diameter:

180mm 7.2 in

Maximum wearing value of the inside diameter:

1.5mm 0.06 in

7. Inspect

· Surface of shoe block

Oil ! Replace the old one or fully clean until no oil is

found

Scrape ! Rub lightly with the abrasive cloth

8. Measure the thickness of the shoe plate, and replace

the shoe plate that does not meet the specifications

or in case brake shoe block is too old.

Standard thickness:

7.0 mm (0.16in)

Maximum thickness wearing value:

1.75mm (0.07in)


MERGE 2-8

Chapter 2

9. Install

· Brake drum

· Rear wheel

WARNING:

Verify that there is no oil or water on the surface of

the brake drum and shoe block.

10. Install:

Wheel nuts

Tightening torque to

90N·m (66.4ft·1b)

NOTICE:

First, screw on the wheel nuts by hand, and then

tighten the nuts diagonally.

11. Upon the completion of the installation, step on the

brake pedal about 10 times to adjust the clearance

between the shoe plate and the drum.


MERGE 2-9

Chapter 2

Inspection of the Accelerator Pedal

1. Inspect

Operating condition of the pedal

In case of unsmooth operation, the pivot should be

lubricated.

2. Inspect

Lateral free travel of the pedal

4mm (0.158 in)

Step on the pedal and replace the pivot in case the

free play is too loose.

Limit value to the free pedal travel:

95mm (3.74in), measured at the top of the pedal

Inspection of the Steering System

State of the Steering Wheel in Steering Operation

1 Inspect

Steering clearance

Push and pull or turn the steering wheel. In case of

over-looseness, the steering wheel or cross-pin type

joint bolts should be tightened.

Limit value to steering clearance of steering wheel:

5 (arc length:15.27mm)

2 Tighten:

Nuts (of steering wheel)



MERGE 2-10

Chapter 2

50N·m (36.9ft·1b)

And tighten:

Bolts (of universal joint

Upper fixing bolt

Lower fixing bolt


22N·m (16.2ft·1b)

3 Re-inspect:

· Steering clearance

Inspection of the Steering Linkage

Removal of Tie Rod Ball Joint

2. Inspect

Ball joints in the following conditions:

· Unsteady operation

· Over-loose free operation

· Bending or scrape

· Damage of dust boot

Refer to Chapter 8 "Steering System"

NOTICE:

In case of any of the above conditions, replace with

a new ball joint.

3. Install:

Steering Gearbox ball joint.


MERGE 2-11

Chapter 2

Inspection of Stub Axle

· Free gap of kingpin bolt, spacer and bushing

a. Park the vehicle on flat surface and apply

parking brake

b. Jack up the front wheels of vehicle

c. Move the wheels lightly

In case the free clearance is too large, the bushing is to

be replaced or the bearing clearance is to be adjusted.

Inspection of the Front Wheel Alignment

Toe-in

1. Park the vehicle on flat surface.

2. Push the vehicle straightly ahead for about 20 steps

to stabilize the suspension.

NOTICE:

Do not pull back the vehicle or step on the brake

pedal, as it will leads to changing of toe-in.

3. Measure:

· Toe-in

Empty 5 8mm (0.20 0.32in)

Full load 0-3mm (0in-0.118in)

In case of non-compliance with standard specified,

adjustment is to be made


MERGE 2-12

Chapter 2

Procedures for the Adjustment of Toe-in:

· Park the vehicle on the flat surface and apply

parking brake.

Loosen the locknut(1) on the ends of the tie rod

Turn the steering tie rod to adjust the toe-in

increase! rotate the steering tie rod so that the

length between two ball joints increases

Decrease! rotate the steering tie rod so that the

length between two ball joints decreases (toe-in

decrease)

· Tighten the locknut on the drag link ball joints.:

· Tightening torque to

40N·m (29.5ft·1b)

Inspection of Tires and Wheel Rim

1. Measure:

· Air pressure


adjustment is to be made

Tire pressure front and rear tires)

200-220kPa

Inspect

· Tire surface

In case of any abrasion, damage, scrape or inset, the

tire is to be replaced.

· Wheel rim

In case of any damage or deformation, the rim is to be

replaced rather than go through the motions of

inspecting the wheel rim.

2. Measure:


MERGE 2-13

Chapter 2

· Wheel tread thickness


replacement is to be made

Maximum wearing value of wheel tread thickness

front and rear tires) 4.0mm(0.16in)

Inspection of the Front Wheel Bearing

1. Wedge blocks onto the rear lower part of the rear

wheels and lift the front body with lifting jack.

2. Move front wheels by hand. Move the front wheel

with the Main Shaft being touched. In case the

clearance is too large, replace the bearing.

Inspection of the Rear Axle Bearing

1. Wedge blocks on the front lower part of the front

wheels, and loosen the rear wheel bolts.

2. Lift the rear body with the lifting jack.

3. Remove:

· Rear wheels

Brake drum

4. Slowly rotate by hand the half shaft of rear axle.

In case of unsmooth or unsteady rotation, the bearing

is to be replaced.

5. Lightly swing the half shaft of the rear axle. In case

that the free gap is too large, the bearing is to be

replaced.

NOTICE:

We do not recommend the replacement of bearing

and bearing sleeve as an individual part. During


MERGE 2-14

Chapter 2

the operation, the quality of fit between half shaft

and bearing or bearing sleeve may deteriorate. In

this case, we usually recommend the replacement of

a new rear axle half shaft assembly.

Inspection of the Shock Damper

1. Inspect:

· For oil leakage

In case of oil leakage, the shock damper is to be

replaced

· Spring

In case of decay, scrape or damage, the shock

damper is to be replaced

Mounting bolts of front shock damper:

Tightening torque

63N·m (46.5ft·1b)

Mounting bolts of the rear shock damper:

Tightening torque

63N·m (46.5ft·1b)


MERGE 2-15

Chapter 2

Inspection of the Seat Belt

1. Binding Force of the Seat Belt

Pull down the seat belt swiftly and the retractor

should respond quickly to seize the belt. The belt,

when loosened, should be retracted back into the

retractor. Otherwise, the seat belt assembly is to be

replaced with new one.

2. Seat Belt Buckle

Buckle the seat belt and pull with force the belt near

the buckle to verify if the buckle can hold the belt

securely.

NOTICE:

In case of damage/scrape/insensitive reaction, the

seat belt assembly is to be replaced with a new one.

Canopy

MERGE 3-1

Chapter 3

Removal of the Canopy

Remove:

1 Disconnect high mounted center light wire

2 Fixing bolts of the canopy

3 Canopy

Install:

Canopy

In the reverse order of the removal procedures

Tightening torque

9N·m (6.6ft·1b)

Removal of Canopy Rods

Remove:

1 Fixing bolt on the rear pillar

2 Fixing bolt on the center pillar E-4

3 Install slip bolt

4 Canopy rod

5 Fixing bolt of front canopy rod

6 Front canopy rod

Canopy

MERGE 3-2

Chapter 3

Install:

Connect the front canopy rod and rear canopy rod, and

tighten the connecting slip bolt

In the reverse order of the removal procedures.

Tightening torque for , ,

22N·m (16.2 ft·1b)

Removal of the Pillar

Remove:

1 Fixing bolt of backrest bracket

2 Backrest bracket

3 Fixing bolt on the rear pillar

4 Fixing bolt on the rear pillar branch

5 Rear pillar

6 Rear pillar branch

7 Fixing bolt on the center pillar connector E-4

8 Center pillar connector

9 Fixing bolt on the center pillar E-4

10. Center pillar

Canopy

MERGE 3-3

Chapter 3

Install:

Pillar


Tightening torque

22N·m (16.2 ft·1b)

Tightening torque for , ,

22N·m (16.2 ft·1b)

Tightening torque

30N·m (22.1 ft·1b)

Body

MERGE 4-1

Chapter 4

1. Removal of the Front Bumper

Remove:

· Bolt

· Front bumper

2. Removal of the Rear Tray

Remove:

· Rear box cover

· Rubber nail

· Screw

· Rear tray

· Clamping nut

3. Removal of the Rear Bumper

Remove:

· Bolt

· Rear bumper bracket

· Bolt

· Rear bumper

Install:

· Front bumper


Tightening torque

63N·m (46.5 ft·1b)

Body

MERGE 4-2

Chapter 4

Install:

· Rear bumper

· Rear bumper bracket

Tightening torque

63N·m (46.5 ft·1b)

Install:

· Clamping nut

· Rear tray

· Rear box cover

Removal of the Seat Cushion

Remove

1. Removal of the seat cushion:

· Handrail fixing bolt

· Handrail

· Handrail bracket fixing bolt

· Handrail bracket

· Upper hinge fixing bolt

· Upper hinge

· Bolts on seat cushion bottom plate

· Seat cushion

· Bottom plate of seat cushion

2. E-2 Removal of the Backrest

· Bolt

· Backrest

3 2+2 Series Backrest Removal

· Bolt

· Rear seat backrest

· Bolt

Body

MERGE 4-3

Chapter 4

· Rear seat backrest bracket

· Backrest

Install:

· Front seat backrest

· Tightening the torque of bolt:

22N·m (16.2 ft·1b)

· Rear seat backrest 2+2 series

· Tightening the torque of bolt:

22N·m (16.2 ft ·1b)

· Seat cushion

· Bottom plate of seat cushion

· Bolts on seat cushion bottom plate

· Handrail bracket

· Handrail bracket fixing bolt

Tightening torque

22N·m (16.2 ft ·1b)

Body

MERGE 4-4

Chapter 4

Removal of Front Cover

Remove

1. Remove:

· Front canopy rod

NOTICE:

Refer to "Removal of Canopy Rod" on page 3-1.

· Instrument panel

· Rubber nail on the upper dashboard

· Fixing nuts on the lower dashboard

Tightening torque

22N·m (16.2 ft·1b)

· Fixing bolt on the lower dashboard

2. Remove:

· Front cover nuts

Tightening torque

9N·m (6.6 ft·1b)

· Front cover bolts

3. Remove:

· Front cover

Install:


Body

MERGE 4-5

Chapter 4

Removal of the Dashboard

Remove

1 Remove:

· Steering wheel cover

· Steering wheel nuts

· Steering wheel

NOTICE:

To remove the scorecard clip, first remove the

screws behind the steering wheel cover.

2. Remove:

· Combination switch connection sheath

· Fixing rubber nail on the upper dashboard

· Fixing bolt on the lower dashboard

Disengage the dashboard

3. Disconnect:

· Connecting line of main switch

· Connecting line of coulomb meter

· Steps connecting line

· Connecting line of multi-functional receptacle

· Plug-in modules of combination switch

connecting line

4 Remove:

· Dashboard

· Combination switch

5. Disengage the clasp and remove the cup holder.

6. Disengage the clasp and remove the baffle.

7. Remove:

Body

MERGE 4-6

Chapter 4

· Edging fender

· Anti-slip pedal

Install:


Tightening the torque of steering wheel nuts

50N·m (36.9ft·1b)

Removal of the Rear Cover

Remove:

1. Remove:

· Seat cushion

· Seat backrest

· Pillar

NOTICE:

Refer to "Removal of Seat Cushion" on page 4-3.

Refer to "Removal of Pillar" on page 3-2.

2. Remove:

· Rear box cover

· Rubber nail

· Screw

· Rear tray

Refer to "Removal of Rear Tray" on page 4-1.

3. Disconnect:

· Rear light connecting line

Body

MERGE 4-7

Chapter 4

4. Remove:

· Fixing bolts of lower hinge

Tightening torque:

7N·m (5.2 ft·1b)

· Hinge

· Rear cover bolt

Tightening torque:

9N·m (6.6 ft·1b)

5. Remove

· Rubber nail of rear cover plate

· Rear cover plate

· Rear cover

Install:


Body

MERGE 4-8

Chapter 4

Rear cover

1. Rear cover 2. Rear cover plate 3. Rear box cover

4. Tray 5. Left rear light 6. Right rear light

7. On-board charging plug box 8. Left ventilating window 9. Right ventilating window

10. Lower hinge 11. Rubber nail 12. Screw

13. Nut 14. Large pan-head bolt 15. Nut

16. Screw 17. Rubber nail 18. Rubber cover of rear pillar

Front Axle

EMERGE 5-1

Chapter 5

Front axle

1. Upper swing arm 2. Split pin 3. Front shock absorber 4. Spindle

5. Lower swing arm 6. Brake disc 7. Oil seal 8. Cone bearing

9. Lower lug shaft 10. Hub connected plate 11. Large dust cover 12. Wheel nuts

13. Slotted nut 14. Split pin 15. Wheel rim decorative cover 16. Front wheel

17. Front wheel rim 18. Inside spacer of Spindle 19. Slotted nut 20. Nut

21. Upper bush 22. Lower bush 23. Bolt 24. Bolt

25. Dust cover 26. Nylon bush 27. Inside spacer of swing arm 28. Air valve

29. Upper lug 30. Bolt

Front Axle

EMERGE 5-2

Chapter 5

Removal of the Front Axle

Remove

1. Park the vehicle on level ground.

2. Apply the parking brake.

3. Loosen: (front wheel) nuts

4. Lift up the front wheels with lifting jack.

Refer to Chapter 1 "Uses of Lifting Jack".

5. Remove:

· (Front wheel) nut

· Front wheel

6. Inspect:

· The operation (of wheel bearing

Rotate the hub connected plate by hand

In case of unsmooth operation, the bearing is

to be replaced with new one.

7. Inspect:

· Free gap (of wheel bearing)

Swing the hub back and forth. In case the free

gap is too large, the slotted nut is to be

tightened. In case the clearance is still too

large, the bearing is to be replaced with new

one.

Front Axle

EMERGE 5-3

Chapter 5

8. Remove:

· Dust cover

9. Remove:

· Split pin

· Slotted nut

10. Remove:

· Brake tongs bolt

Tightening torque

23N·m (17.0 ft·1b)

· Brake tongs

11. Remove:

· Hub connected plate (of front wheel)

Knock at the connected plate with a soft

hammer.

Front Axle

EMERGE 5-4

Chapter 5

12. Remove:

· Brake disc bolt

Tightening torque

23N·m (17.0 ft·1b)

· Brake disc

Standard thickness of brake disc

4 mm (0.16 in)

Maximum wearing thickness

1 mm (0.04 in)

13. Remove:

· Bolt

Tightening torque

23N·m (17.0 ft·1b)

· Fore wheel brake shoe

Standard thickness

7 mm (0.28 in)

Maximum wearing thickness

1 mm (0.04 in)

14. Inspect:

· Spindle free gap

Swing the Spindle. In case the free gap is fairly

large, the inside spacer and bush of the

Spindle are to be replaced.

Front Axle

EMERGE 5-5

Chapter 5

NOTICE:

The inside space and bush should be replaced

together.

15 Remove:

· Removal of Drag Link Ball Joint

Please refer to Chapter 2 "Removal of Drag

Link Ball Joint".

· Split pin

· Pivot slotted nut

· Spindle lug

· Spindle

· Inside spacer of Spindle

· Bush of Spindle

16. Inspect:

· Free gap of swing arm

Swing the swing arm. In case the free gap is

fairly large, the inside spacer and nylon bush

of the swing arm are to be replaced.

NOTICE:

The inside space and nylon bush of the swing

arm should be replaced together.

Front Axle

EMERGE 5-6

Chapter 5

17. Remove:

· Front shock absorber bolt

Tightening torque

60N·m (44.2 ft·1b)

· Front shock absorber

· Swing arm bolt

Tightening torque

60N·m (44.2 ft·1b)

· Upper and lower swing arms

· Dust cover

· Inside spacer

· Nylon sheath

Inspect

1. Wheel

In case of scrape/bending/deformation, the

wheel is to be replaced.

2. Hub connected plate

In case of scrape/damage, the hub connected

plate is to be replaced.

3. Bearing (of hub connected plate)

In case of unsmooth operation of the

connected plate or wheel as a result of the

bearing, the bearing is to be replaced.

4. Oil seal

In case of abrasion/damage, the oil seal is to

be replaced.

Procedures for the replacement of hub

connected plate bearing and oil seal cover:

· Clean the interior of hub connected plate.

Front Axle

EMERGE 5-7

Chapter 5

· Remove the oil seal and bearing with the

special bearing puller.

· Install new oil seal cover and bearing in the

installation procedures mentioned above.

NOTICE:

Use a hold-down clamp that is consistent with

the diameter of bearing and inside loop of oil

seal cover.

Caution

Do not knock at the bearing roller and bracket. It

is enough that it reaches the center of the inner

loop.

5. Spindle

In case of damage/deformation, the Spindle is

to be replaced.

6. Front shock absorber

In case of spring deflection/oil leakage and

surface scrape, the front shock absorber is to

be replaced.

7. Swing arm

In case of damage/deformation, the swing arm

is to be replaced.

Install

Move back to the procedures of “removal”

Note the following:

1. Warning

The split pin, once removed, must be replaced

with new one.

2. Install:

· Front wheel

· Wheel nut (of front wheel):

Tightening torque

70N·m (52.0 ft·1b)

Driving Axle

EMERGE 6-1

Chapter 6

Driving axle

1. Outer tube of left half axle 2. Left half axle 3. Electric motor 4. Differential gear

5. Outer tube of right half axle 6. Right half axle 7. Brake drum 8. Brake base plate

9. Brake shoe plate 10. Cable retaining plate 11. Wheel rim 12. Air valve

13. Tire 14. Wheel rim decorative cover 15.Retaining plate 16. Bearing 6206

17. Bearing fixing bush 18. Oil seal 19. Spring washer 20. Flat washer

21. Brake rocker arm 22. Locating dowel 23. Wheel cylinder 24. Locating dowel

25. Upper tension spring 26. Lower tension spring 27. Wheel nuts 28. Return spring

29. Bolt 30. Spring washer 31. Bolt 32. Spring washer

33. Nut 34. Bolt 35. Clipping spring 36. Bolt

37. Adjusting ratchet 38. Left tension spring 39. Right tension spring

Driving Axle

EMERGE 6-2

Chapter 6

Removal of the Driving Axle


2. Lift the rear body with the lifting jack before

putting a suitable bracket under the frame.

Refer to Chapter 1 "Use of Designated Lifting

Jack".

3. Wedge blocks onto the front lower part of the

front wheels.

4. Disconnect:

All the connecting lines of the electric motor.

5. Remove:

· Six bolts of the electric motor

· Electric motor

Refer to Chapter 9 "Removal of Motor".

6. Put an oil tray under the differential gear,

unscrew the bleeding bolt to discharge all the

lubricating oil in the differential case.

7. Remove:

· Wheel nut (of rear wheel)

· Rear wheel

Driving Axle

EMERGE 6-3

Chapter 6

8. Remove:

· Lower fixing nut of rear shock absorber

Tightening torque

63N·m (46.5ft·1b)

· rear shock absorber

· Rear axle and rear swing arm fixing nut

Tightening torque

63N·m (46.5ft·1b)

· U-bolt

· Driving axle

9. Remove:

Brake hub

NOTICE:

In case the brake hub is difficult to remove,

knock out the hub with rubber hammer.

10. Inspect:

· Half axle operation

· Rotate the half axle connected plate with hand,

and in case of unsteady rotation or abrasion,

the half axle assembly is to be replaced.

Driving Axle

EMERGE 6-4

Chapter 6

11. Remove

· Clipping spring

· Locating dowel

· Upper and lower brake retracting spring

· Brake shoe

Turn the locating dowel with spring or pincer

pliers to separate the clipping spring and

locating dowel of brake shoe.

12. Remove:

· Fixing bolt of half axle of rear axle

· Half axle assembly of rear axle

· Brake base plate

NOTICE:

Knock out the half axle wheel rim of the rear axle

lightly with a rubber hammer.

13. Remove:

· Fixing bolt of half axle outer tube

Tightening torque

55N·m (40.6 ft·1b)

· Half axle outer tube

Driving Axle

EMERGE 6-5

Chapter 6

Inspect and test

1. Measure:

· Inside diameter of brake drum

· Thickness of brake shoe

Refer to Chapter 2. In case of non-compliance

with the specification, replacement is to be

made.

2. Inspect

· Bottom plate of brake shoe plate

· Brake drum

In case of deformation/scrape/damage,

replacement is to be made.


In case of scrape/bending/deformation, the

wheel is to be replaced.

NOTICE:

We do not recommend the replacement of

bearing and bearing sleeve as an individual part.

During the operation, the quality of fit between

half shaft and bearing or bearing sleeve may

deteriorate. In this case, we usually recommend

the replacement of a new rear axle half shaft

assembly. In addition, due to the complex

internal structure of the brake, we recommend

that the maintenance personnel replace or

adjust one brake with another one as the

reference during the service.

· Rear axle tube

In case of scrape/bending/damage,


Driving Axle

EMERGE 6-6

Chapter 6

Install

In the reverse order of the “removal”

procedures

Note the following.

1. Lubricate

· External surface of the bearing

Basic grease

2. Install:

· Brake base plate


· Bolt

· Spring

· Nut

Tightening torque

22N·m (16.2 ft·1b)

3. Install:

· Half axle outer tube of rear axle

· Bolt

Tightening torque

60N·m (44.3 ft·1b)

4. Install

· Brake shoe

· Upper tension spring

· Lower tension spring 11

· Locating dowel

· Clipping spring

Driving Axle

EMERGE 6-7

Chapter 6

Procedures for the installation of brake shoe:

· Apply the high temperature grease over the two

ends of the metal support of the brake shoe.

WARNING

In handling the brake shoe, ensure that the

hands are clean and the shoe plate surface is

not tainted with grease.

5. Install

· Brake drum

· Rear wheel assembly

· Wheel nut (of rear wheel)

Tightening torque

70N·m (51.7 ft·1b)

6. Install

· Bleeding bolt

Tightening torque

70N·m (51.7ft·1b)

Remarks:

Apply 1100mL lubricating oil (GL -4 or GL- 5) to the

rear axle.

7. Install

· Oil filler screw plug

Driving Axle

EMERGE 6-8

Chapter 6

Gearbox

1. Gearbox body 2. Bottom cover of differential gear 3. Input shaft 4. Middle gear

5. Middle shaft 6. Oil filler plug 7. Ring gear 8. Differential gear

9. Bearing pressing block 10. 6008 bearing 11. Bearing 6303RS 12. Bearing 6005RZ

13. Inner clasp 14. Rubber cover 15. Gear bush 16. Oil seal

17. Bearing bush 18. Bolt 19. Spring washer 20. Bolt

21. Copper washer 22. Spring washer 23. Bolt 24. Stud bolt

25. Nut 26. Bleeding bolt

Driving Axle

EMERGE 6-9

Chapter 6

Removal of the Differential Gear

1 Remove:

· Differential gear

· Fixing bolt of differential gear

· Bottom cover of differential gear

Caution

The bottom cover of the differential gear should

be pried up by a flat-head screwdriver. Please

note not to damage the sealing surface of the

box or deform the bottom cover of the

differential gear.

2 Remove:

· Bearing pressing block bolt

· Bearing pressing block

· Differential with ring gear and bearing

Driving Axle

EMERGE 6-10

Chapter 6

3 Disassemble:

· Ring gear

· Differential gear assembly

4 Remove:

· Sealing rubber cover (both ends)

5 Remove:

· Oil seal

· Clip spring

· Bearing fixing bush

· Bearing

· Input shaft

6 Remove:

· Clip spring (from countershaft gear

· Bearing

· Gear bush

· Countershaft

· Countershaft gear

Driving Axle

EMERGE 6-11

Chapter 6

Procedures for the removal of countershaft

gear

1 Push out the countershaft gear from the

bearing inner ring.

2 Remove the bearing with bearing extractor.

3 Repeat Step 1 to remove the countershaft

gear on the other side.

Inspection

1. Inspect:

· Ring gear

· Differential gear assembly

In case of damage or abrasion, replacement is

to be made

· Bearing

In case of erosion damage, replacement is to

be made

Install

In the reverse order of the removal procedure.

Note the following:

2. Tighten:

· Differential gear bolt that connects the ring

gear and differential gear assembly

Tightening torque

54N·m (39.8ft·1b)

Driving Axle

EMERGE 6-12

Chapter 6

3. Tighten

· Differential bearing pressing block bolt

NOTICE:

Clean the surface of differential gear and box

bottom cover.

Apply 856 sealant to differential gear surface

and 10 bolt holes.

4. Tighten:

Differential gear bottom cover bolt

NOTICE:

Tighten the bolts diagonally from the smallest

type in two phases.

Install:

In the reverse order of the "removal" procedure, and

note the following.

1 Install:

Rear axle and rear rocker U-bolt

Tightening torque

50N·m (36.9ft·1b)

2. Apply Oil:

Recommended oil:

GL-4 or GL-5 gear oil

Oil volume: 1100mL

Brake System

EMERGE 7-1

Chapter 7

Brake System

1. Brake pedal 2. Parking brake handle 3. Brake caliper 4. Rear brake

5. Front brake disc 6. Brake master cylinder 7. Brake drum 8. Boot

9. Brake pedal base 10. Brake pedal sealant 11. Brake shoe plate 12. Brake handle base

13. Return spring 14. Nut 15. Locating dowel 16. Flat washer

17. Split pin 18. Bolt 19. Nut 20. Bolt

21. Parking switch 22. Nut 23. Bolt 24. Bolt

25. Nut 26. Cable 27. Oil hose 28. Iron oil tube

29. Bolt 30. Reservior 31. Clamp 32. Tee tube

Brake System

EMERGE 7-2

Chapter 7

Brake Pedal

1. Measure:

· Free play of brake pedal;

13mm (0.512 in

In case of non-compliance with the

specification, the brake master cylinder is to be

replaced.

2. Remove

· Anti-slip pedal

· Protective cover plate

Refer to relevant content in Chapter 2.

· Brake pedal fixing bolt

· Brake pedal fixing nut

Tightening torque

50N·m (36.9 ft·1b)

· Brake pedal

· Fixing bolt of brake master cylinder

· Fixing nut of brake master cylinder

Tightening torque

45N·m (33.2 ft·1b)


· Brake pipe

· Tee tube

Inspect:


· Brake pipe

· Tee tube

In case of oil leakage/deformation/damage,


Brake System

EMERGE 7-3

Chapter 7

Parking brake handle

1. Measure:

· Free play of parking brake handle;

15mm (0.591in)

In case of non-compliance with the

specification, the free play is to be adjusted.

2. Remove

· Boot

3. Inspect:

· Hand brake cable

In case of oil leakage/deformation/fall-off,


Brake System

EMERGE 7-4

Chapter 7

Accelerator pedal

1. Accelerator pedal 2. Accelerator 3. Accelerator bracket 4. Pivot

5. Split pin 6. Pin axle 7. Washer 8. Split pin

Steering System

EMERGE 8-1

Chapter 8

Steering system

1 steering wheel 2 cover of steering cover 3 nut of steering wheel

4 bearing 5 inner snap ring 6 steering shaft

7 outer snap ring 8 protective sleeve of steering shaft 9 turn signal stalk

10 protective sleeve for wire harness 11 block of steering column

12 bolt 13 bolt 14 nut 15 universal joint spline

16 spline bearing of universal joint 17 dustproof cover of universal joint 18 nut

19 lock washer 20 flat washer 21 steering gear housing 22 nut

23 outer snap ring 24 tape 25 dustproof cover 26 adjusting nut

27 adjusting cap 28 stress spring 29 hold downs 30 oil seal

31 small gear bearing 32 inner snap ring 33 outer snap ring 34 dustproof cap

35 bearing 36 bushing 37 steering rod 38 gear

39 stopple washer 40 dustproof sleeve 41 ball joint 42 slotted nut

43 cotter pin 44 nut 45 tape

Steering System

EMERGE 8-2

Chapter 8

Removal of the Steering System



3. Put a suitable bracket under the frame and lift

up the front wheels with lifting jack.

Refer to Chapter 1 "Recommendation for Use

of Lifting Jack".

4. Remove:

· Steering wheel cover plate

· Steering wheel nuts

· Steering wheel

5. Remove:

· Dashboard

Please refer to Chapter 4 "Removal of the

Dashboard".

· Disconnect the connecting line of turn signal

stalk

·Sleeve of turn signal stalk cable

· Bolt

· Turn signal stalk

6. Remove:

· Upper fixing bolt of the block of steering

column

Tightening torque

20N·m (14.8 ft·1b)

· Lower fixing nut of the block of steering

column

Steering System

EMERGE 8-3

Chapter 8

Tightening torque

50N·m (44.6 ft·1b)

· Upper fixing bolt of universal joint

Tightening torque

25N·m (18.4 ft·1b)

· Steering column assembly

7. Disassemble:

· Outer clasp

· Inner clasp

· Steering shaft

· Bearing

NOTICE:

Press the steering shaft out of the bearing on

one side with the hydraulic press, and extract

the bearing with universal bearing extractor.

Extract the bearing on the other side in the

same method. The bearings, once removed,

must be replaced with new ones.

Removal of the Steering Gear

1. Remove:

· Split pin

· Slotted nut

· Lower fixing bolt on the universal joint

Tightening torque

25N·m (18.4 ft·1b)

· Universal joint assembly

· Fixing bolt on the steering gear

Steering System

EMERGE 8-4

Chapter 8

Tightening torque

45N·m (33.2 ft·1b)

· Steering gear

Disassembly of the Steering Gear

1. Disassemble:

· Drag link ball joint of the steering gear

· Secure the drawbar of the steering gear with

one spanner, and loosen the locknut with

another spanner.

· Tape

NOTICE: The tape, once removed, will be a

destroyed, and should be replaced with a new

one.

2. Disassemble:

· Dust boot of steering gear

3. Disassemble:

· Thrust washer

· Drawbar of steering gear

Steering System

EMERGE 8-5

Chapter 8

EMPHASES

Observe whether there is a skewed slot on one

side of the rack of steering gear. This skewed

slot is designed to prevent the drawbar of

steering gear from loosening. To re-install it,

the thrust washer should be fixed in the skewed

slot.

4. Disassemble:

· Locknut

· Adjusting cover

· Spring

· Pressing block

NOTICE:

Seize and pull out the pressing block with

nipper pliers, which can make the disassembly

easier.

5. Disassemble:

· Oil seal

· Inner clasp

· Outer clasp

· Pinion shaft

NOTICE: The oil seal, once removed, must be

replaced with new one. Turn the pinion shaft

with hand to inspect the operation of the

bearing. In case of unsmooth operation, the

bearing should be replaced.

Steering System

EMERGE 8-6

Chapter 8

6. Disassemble:

· Rack of steering gear

7. Inspect:

· Steering gear bush

· Deep groove ball bearing

NOTICE:

We do not recommend the replacement of worn

parts in the steering gear individually. To ensure

sound operating performance, we usually

recommend the replacement of a new steering

gear assembly.

· Whether the operation of rack is smooth.

NOTICE:

Improper adjustment or lack of lubrication of

the gear teeth may result in irregular abrasion.

· Whether the dust boot has ruptures or

scrapes

Steering System

EMERGE 8-7

Chapter 8

· Whether the ball joint has the following

symptom:

Unsmooth operation

Over-loose free gap

Bending or deformation

Damage of dust boot

NOTICE:

In case of any of the above condition, replace

with a new ball joint.

Install:

Note the following:

1. Lubricate

· Bearing

· Rack

· Pinion shaft

· Oil seal

Apply a thin layer of grease

Install:

· In the reverse order of the removal

procedures. Refer to the schematic diagram

of system parts.

Adjust the tightening torque of the cover:

1.5-2 N · m (1.1ft·1b-1.48ft·1b)

NOTICE: The steering gear should have no

clamping stagnation when the left and right

racks turn to the final positions. When they

return to the middle position, the free gap of the

steering wheel should be 45mm, or else the

steering gear assembly must be replaced.

Adjust the tightening torque of locknut

35N·m (25.8ft·1b)

Electric Component

MERGE 9-1

Chapter 9

.

WARNING

• Please refer to Chapter 1 “Protection for

Electrical Safety”.

Key switch removal

1. Turn Tow/Run switch to TOW.

Please refer to Chapter 1 “Protection for Electrical

Safety”.

2. Take out the key from the key switch.


4. Remove the middle electrical regaining plate.

5. Pull out the instrument panel slowly (Note: do not

pull apart the connecting wire of the instrument

panel), pull out the wire of the key switch until the

plug-in package connecting the key switch wire to

the main cable appears, disengage the plug-in

package of the key switch wire from that of the

main cable.

6. Hold the key switch and remove the switch lock

nut from outboard of instrument panel.

7. Check

Refer to “Check Procedure 6—Circuit check for

key switch and accelerator pedal switch” of

Chapter 10, replace the part in case of any

inconsistency.

Key switch installation

Back to the removal steps

Electric Component

MERGE 9-2

Chapter 9

Removal of forward/reverse gear switch

1. Turn Tow/Run switch to TOW


Safety”.




5. Remove the connecting wire from gear switch.

6. Press the snap locks on the upper and lower

ends of the switch, push switch out of the

housing.

7. Check:

Continuity of the gear switch.

Refer to “Check Procedure 10—forward/reverse

gear switch” of Chapter 10, replace the part in

case of counter conditions.

Installation of forward/reverse gear switch


NOTE:

The red, black/yellow and blue/white wires must

be connected correctly at relevant positions on

the gear switch.

removal of headlight power switch

1. Turn Tow/Run switch to TOW


Safety”.


3. Apply the parking brake..


Electric Component

MERGE 9-3

Chapter 9

5. Remove the connecting wire from emergency

switch.

6. Press the snap locks on the upper and lower ends

of the switch, push switch out of the housing.

check

Continuity of the emergency switch

.

Installation of emergency switch


Note

The red, black/yellow and blue/white wires must be

connected correctly at relevant positions on the

emergency switch

Installation of Battery power level indicator

Electric Component

MERGE 9-4

Chapter 9

Check:

Refer to “Check Procedure 12 -- Battery

discharge meter” in Chapter 10




Battery discharge meter installation


NOTE:

The red, red/green and black wires must be

connected correctly at relevant positions on the

battery discharge meter.

Horn removal





Safety”.

4. Disconnect the horn wire.

5. Remove the horn set bolt and remove the

horn.

6. Check the horn for continuity.

Replace the part in case of un-continuity.

Electric Component

MERGE 9-5

Chapter 9

Horn installation

Return to disassembling steps

NOTE:

The horn wire must be connected correctly.

The tightening torque of the horn set bolt is:

9N m (6.6ft 1b)

Combination switch removal



3. Turn Switch Tow/Run to TOW.


Safety”.

4. Remove the protective sleeve for the wire

harnesses of combination switch.

5. Remove the set bolt from the top of the

switch.

6. Remove the instrument panel; refer to the

relevant contents in Chapter 4.

7. Disconnect the wire plug-in package of the

combination switch and remove the combination

switch .

Electric Component

MERGE 9-6

Chapter 9

8. Turn the switch lever and check the relevant

gears for continuity, replace the part in case of

un-continuity.

Combination switch installation

Back to disassembling steps

Controller removal



3. Turn Switch Tow/Run to TOW.


Safety”.

4. Remove the trunk lid.

5. Remove the rear plate plastic screw.

6. Remove the rear plate.

7. Remove the safety belt buckle set bolt

Tightening torque

63N m(46.5ft 1b)

8. Remove the safety belt buckle

9. Disconnect all wires and multi-wire connectors

from the controller.

Electric Component

MERGE 9-7

Chapter 9

Control circuit

Electric Component

MERGE 9-8

Chapter 9

Lighting circuit

10. Unscrew the 4 screws on the controller mount

and remove the controller.

Controller installation

Back to the removal steps.

Check the electric vehicle for normal operation:

• When Forward/Reverse gear switch is on

FORWARD position, make sure the electric vehicle

is running forward.


REVERSE position, make sure the electric

vehicle is running backward. When

Electric Component

MERGE 9-9

Chapter 9

Forward/Reverse gear switch is on REVERSE

position, the reverse buzzer should sound a

warning tone.


NEUTRAL position, make sure the electric

vehicle remains still.

Charger receptacle removal



3. Disconnect the battery cable according to the

directions.


Safety”.

4. Remove the red wire and the black wire from the

positive binding post on the rear of charger

receptacle.

5. Screw off the 4 screws fixing the charger

receptacle plate to the socket bottom and the car

body.

6. Remove the charger receptacle retaining plate

and charger receptacle.

7. Check:

Check the receptacle for cracks, poor contact and

wear and replace the part if necessary.

Charger receptacle installation


Battery removal



3. Remove the seat pad assembly.

Electric Component

MERGE 9-10

Chapter 9

4. Disconnect the battery cable according to the

directions.


Safety”.

5. Remove the nut on the battery hold down.

6. Remove the battery hold down

7. Remove the battery with a special battery lifting

tool.

8. Check:

Check the electrolyte level of the battery; add

distilled water to 13mm above the plate electrode

if the level is below the plate electrode.

Battery installation


NOTE:

The battery must be removed with a special

battery lifting tool.

DC converter removal



3. Remove the seat pad assembly.



Safety”.

5. Disconnect the wire plug-in package of DC

converter.

6. Remove the four set bolts.

Electric Component

MERGE 9-11

Chapter 9

7. Remove the DC converter.

DC converter installation


Removal of DC changeover contactor and

diode assembly



3. Remove the seat pad assembly



Safety”.

5. Remove the watertight cover of DC changeover

contactor .

6. Remove the lock nut on the binding post of

changeover contactor.

7. Remove the connecting wire, then remove the

diode assembly .

NOTE:

Keep in mind the polarity of the diode to prevent

incorrect installation resulting in short circuit and

electric element burning out;

8. Remove the DC changeover contactor.

9. Check:

• The continuity of DC changeover contactor coil.

Replace the part in case of un-continuity.

• The continuity of diode assembly.

Replace the part in case of abnormality.

Electric Component

MERGE 9-12

Chapter 9

Installation of DC changeover contactor and

diode assembly


NOTE:

The diode must be installed with a correct

polarity.

Motor removal





Safety”.

4. Mark a line at the motor interface with a marking

pen.

5. Hold the binding post with two wrenches;

disconnect the wire from the connecting terminal

of the motor.

6. Remove the 6 bolts fixing the motor.

Marking line

Electric Component

MERGE 9-13

Chapter 9

7. Wrap the motor at the mid position with a wide

band, lift the motor carefully and move it to the left

horizontally, then place it on the ground gently.

NOTE:

The motor is heavy, lift and place with care.

8. Check:

• Inside short circuit

Use a multi meter set to 200!, connect the

black probe (-) to the motor case. Scrape off

the paint to ensure a good contact. Connect

the red probe (+) to terminals A1, A2, F1 and

F2 respectively. The multi meter should show

no connection.

• Armature circuit opening

Use a multi meter set to 200!, connect the red

probe (+) to A1 and connect the black probe (-)

to A2. The multi meter should show

connection.

• Exciting circuit opening

Use a multi meter set to 200!, connect the red

probe (+) to F1 and connect the black probe (-)

to F2. The multi meter should show

connection.

In case of above reading errors, have the motor

repaired by a professional.

Electric Component

MERGE 9-14

Chapter 9

Motor installation


NOTE:

Match the marking line during motor installation.

Removal of bulb of headlight and front turn

signal light




Please refer to Chapter 1 “Protection for


4. Disconnect the connecting wire of the headlight

and the cable plug-in package;

5. Remove the 4 screws fixing the headlight with a

Philips driver;

6. Remove the headlight; pull apart the power cord

from the headlight bulb;

7. Remove the 2 screws fixing the bulb with a screw

driver and take out the headlight bulb;

8. Turn the lamp receptacle of the front turn signal

light and remove the turn signal lamp bulb;

9. Check the bulbs of the headlight and the turn

signal lamp for continuity and replace the part in

case of un-continuity.

Headlight installation

Electric Component

MERGE 9-15

Chapter 9

Back to the above operation steps

NOTE:

Wiring of positive/negative poles of the bulb,

wiring position of high/low beam.

Tail light removal

Any defective or dim tail light shall be replaced.





Safety”.

4. Remove the tail light with a flat head screwdriver.

CAUTION:

Don't break the 4 snaps on the lens; the tail light

must be replaced if any of them is broken.

5. Disconnect the wire.

Tail light installation

Back to removal steps

High mount stop lamp removal




Please refer to Chapter 1 “Protection for


4. Remove the screw with a screwdriver .

Electric Component

MERGE 9-16

Chapter 9

5. Disconnect the connector of the high mount stop

lamp .

High mount stop lamp disassembly

1. Remove the screw .

2. Rotate the lamp receptacle; remove the wire

harness with the bulb .

3. Check the continuity,

Replace the bulb assembly with wire harness in

case of un-continuity .

High mount stop lamp installation

Back to removal steps

Wiper removal





Safety”.

4. Disconnect the wiper.

5. Remove the wiper arm.

6. Remove the fixing nut of wiper motor.

Electric Component

MERGE 9-17

Chapter 9

Removal of inner mirror

1.Take out the key from the key switch.

2. Apply the parking brake


4. Take off the connector of inner mirror

5. Take off fixed nut of inner mirror

6. Take out the mirror

Installation of inner mirror

1. Stick the sponge glue and clip on the bracket

of inner mirror

2. Fix the bracket on windshield frame

3. Take off white lense

4.Fix the mirror on the bracket

Electric Component

MERGE 9-18

Chapter 9

5 Cover the light with white lense.

6.fix the wire clip on the windshield frame

along left side of it.

7.connect the connector( connect one

side of the two output of connector of

inner mirror with wire, the other side with

the output wire of wiper

8. fix the wires of inner mirror along the

wire clip

Troubleshooting

MERGE 10-1

Chapter 10

Troubleshooting Instructions Part 1

Symptom Possible causes Correction action

Battery - dead Charge the battery.

Battery - battery wiringCheck the wiring of the electric vehicle. Refer to the

wiring diagram on page 9-7.

Circuit of key switch and

accelerator switch

Check the wire of key switch and accelerator switch

for poor contact and disconnection.

Key switch failureRefer to “Check Procedure 6—Circuit of key switch

and accelerator pedal switch”.

Accelerator pedal switch

failure

Page 10-6, “Check Procedure 6—Circuit of key

switch and accelerator pedal switch”. Refer to

“Check Procedure 2--Accelerator signal voltage”.

Forward/reverse gear switchPage 10-11, “Check Procedure 10—forward/reverse

gear switch”.

Controller overheated Before restarting, cool the controller and make sure

the electric vehicle is not overloaded.

Controller plug

Check the controller plug for poor contact and

broken wire. Refer to “Check Procedure

7--Controller signal”.

High pedal check Drive in correct way

Motor failure Chapter 12 “Motor”

Controller failure Replace controller. Refer to “Controller removal” in

Chapter 9.

The electric vehicle

can't be started

Speed sensor disconnection or

failure

Page 10, “Check Procedure 9—Motor speed

sensor”.

Wrong speed setting The set max. speed of the electric vehicle can only

be changed by PC programming.

Circuit – incorrect wiring Check the wiring of the electric vehicle. Refer to the


Battery - dead Charge the battery.

Accelerator failure Refer to “Check Procedure 2--Accelerator signal

voltage”

Motor--poor contact of wire. Check and fasten all connectors of the motor.

Motor failure Replacement motor. Refer to “Motor removal” in

Chapter 9.

Controller failure Replace controller. Refer to “Controller removal” in

Chapter 9.

Brake – improperly adjusted

Under inflated or flat tire Refer to relevant maintenance and repair

instructions.

Electric vehicle runs

slowly

Electric vehicle overload Remove the load, make sure the electric vehicle is

not overloaded.

Troubleshooting

MERGE 10-2

Chapter 10

Part 1 of Troubleshooting Instructions, continue

Symptom Possible causes Correction action

Circuit – incorrect wiringCheck the wiring of the electric vehicle. Refer to

the wiring diagram on page 9-7.


can be started, but the

motor braking device

does not operate.

Speed sensor disconnection or

failure

Refer to “Check Procedure 9—Motor speed

sensor”.

Forward/reverse gear

switch—incorrectly connected or

damaged.

Refer to, “Check Procedure

10—forward/reverse gear switch”.

Motor – incorrect wiring.Check the wiring of the motor. Refer to the


Electric vehicle can

only run forward or

backward.

Controller—incorrect wiring or

controller piece failure.

Check the wiring of the electric vehicle. Refer to

the wiring diagram on page 9-7.

Battery charger connection—wire

poor contact of the receptacle or

battery.

Check the wire for connection and fasten it

when necessary.


can be started, but the

battery charger can't

charge the battery. Battery charger Refer to relevant maintenance and repair

instructions for battery charger.

DC converter failure Replace DC converter

Lighting fuse blowing out Replace fuse

Auxiliary contactor failure Replace contactor

Bulb damaged Replace bulb

Headlight failure

Combination switch failure Replace combination switch


Turn signal lamp bulb Replace bulb

Flasher failure Replace flasher

Turn signal lamp

failure



Lighting fuse blowing out Replace fuse

Auxiliary contactor failure Replacement contactor

Tail light damaged Replace tail light


Tail light failure




Brake switch failure Replace brake switch

High mount stop lamp

failure

High mount stop lamp bulb damaged Replace high mount stop lamp bulb

Odometer parking lamp bulb failure Replace odometer parking lamp bulb

Parking switch failure Replace switch Parking lamp failure

Bulb damaged Replace bulb

Troubleshooting

MERGE 10-3

Chapter 10

Check procedures

With the following procedures, the entire electrical system can be checked without disassembling the

electric vehicle.

WARNING

• If the wires are removed or replaced, make sure that the wires and harnesses are arranged

and fixed correctly. Wires and harnesses not arranged and fixed correctly can result in

electric vehicle failure, property damage and casualties.

Index for check procedures

1. Battery/ voltage check

2. Accelerator signal voltage

3. Motor voltage at A1 and A2

4. TOW/RUN switch

5. Battery voltage (under voltage)

6. Circuit of key switch and accelerator pedal switch

7. Controller signal

8. Charger

9. Motor speed sensor

10. Forward/reverse gear switch

11. Backing buzzer

12. Battery discharge meter

13. High mount stop lamp

14. Wiper

15. Flashing light

Troubleshooting

MERGE 10-4

Chapter 10

Check Procedure 1—Battery / voltage check

NOTE: to perform the following check procedures, the battery should be maintained properly and

charged fully.

Use a DC multimeter set to 200V, connect the black (-) probe to the negative output binding post of the

battery and connect the red (+) probe to the positive wire of the battery.

Check Procedure 2--Accelerator signal voltage

Please refer to Chapter 1 Protection for Electrical Safety.

1. Use a DC multimeter set to 20V, connect the black (-) probe to the negative binding post of the

battery and connect the red (+) probe to Wire 7 (black/white wire). The reading should be around 0V

at the original position of the pedal. Press down the accelerator pedal slowly; observe the reading

on the multimeter. When the pedal is pressed, the reading should be increased by 0V-5V until the

pedal is pressed down completely.

2. If the reading is not increased while pressing the pedal, the accelerator should be replaced.

3. If the reading is lower than 4.5V when the pedal is pressed down completely, the electric vehicle can

not run at the rated max speed. Please check whether the accelerator is in good condition.

Check Procedure 3-- Motor voltage at A1 and A2

Please refer to Chapter 1 “Protection for Electrical Safety”.

1 Jack up the rear axle of the electric vehicle so that the rear wheels are in the air.

2. Check that the battery is wired correctly, then connect the black (-) probe of a multimeter set at

200V DC to motor terminal A2 and connect the red probe (+) to motor terminal A1.

3. With TOW/RUN switch on position RUN, turn the Switch Forward/Reverse to FORWARD, then

press the accelerator pedal slowly.

4. While the accelerator pedal is pressed, the voltage reading should be increased from 5V when the

accelerator pedal switch is closed to 48V when the accelerator pedal is pressed down completely.

4.1 If no voltage reading is displayed, check the accelerator. Refer to “Check Procedure

2--Accelerator voltage”.

4.2 Disconnect the battery cable according to the directions. Please refer to Chapter 1 “Protection

for Electrical Safety”.

4.3 Check the continuity of motor binding posts A1, A2 and F1, F2. In addition, check all motor

wires for continuity. Refer to “Motor” in Chapter 12.

Troubleshooting

MERGE 10-5

Chapter 10

Check Procedure 4 - TOW/RUN switch


1. Use a multimeter, set it at diode testing position, connect the black (-) probe to one connecting

terminal of towing switch and put the red (+) probe on the connecting terminal on the other side.

2. When TOW/RUN switch is on position RUN, the multimeter should show a conducting state. When

TOW/RUN switch is on position TOW, the multimeter should show a disconnect state.

3. Check the continuity of the other group terminals with the above mentioned method.

4. If the continuity reading is not correct, replace the TOW/RUN switch.

Check Procedure 5—Battery voltage


1. Before starting this check procedure, connect the battery properly and charge it fully. Use a 48V

battery discharger. Connect the positive electrode (+) wire to the positive binding post of Battery 1

and connect the negative electrode (-) wire to the negative binding post of Battery 6. Write down the

voltage reading of the discharger.

2. Turn on the discharger and record the voltage reading of the battery at under voltage.

3. For a fully charged battery in good condition, the reading should be lower than 41 at under voltage.

4. A reading of 41V indicates a discharged or faulty battery. Each battery should be checked in under

voltage state with a multimeter.

5. Don’t start the discharger if the voltage is lower than 41V. If the battery voltage is lower than 41V, it

indicates the battery is completely discharged or faulty.

6. Record the voltage reading of the battery pack in under voltage state allows a more accurate

diagnosis on battery condition. When the discharger is started, it will result in battery pack under

voltage, repeated operations are helpful to determine the failure of one or more batteries in the

battery pack. The voltage of the battery not measured at under load may not show the actual

condition of the battery. For more information on battery, refer to Chapter 11 “Battery and Charger”.

Check Procedure 6—Circuit check for key switch and accelerator pedal switch

1. Disconnect the battery cable according to the directions. Please refer to Chapter 1 “Protection for


2. Check the key switch.

3 Remove the middle instrument panel. Refer to "Key switch removal" in Chapter 9.

4 Use a multimeter set at 200!; connect the red (+) probe to the key switch terminal connected with a

red wire. Connect the black (-) probe to the other terminal of the key switch.

Troubleshooting

MERGE 10-6

Chapter 10

5 When the key switch is on position OFF, the multimeter should show an open circuit condition.

6 When the key switch is on position ON, the multimeter should show a conducting state.

7 If other readings are obtained, replace the key switch. Refer to "Key switch removal" in Chapter 9.

8 If the key switch operates as above, install the instrument panel in the reverse sequence of removal

and perform the following operations.

9 Check accelerator pedal switch.

NOTE: Before operation, make sure the key switch operates properly and the key switch and the

instrument panel are installed correctly.

9.1 When the battery is connected, use a multimeter set at 200V DC, connect the black (-) probe to

the negative binding post of Battery 6 and connect the red (+) probe to the pedal switch output

wire (Wire 3).

9.2 When the Tow/Run switch is on RUN position, the key switch is ON and Forward/Reverse gear

switch is on NEUTRAL, the voltage reading should be 0V. When the accelerator pedal is

depressed, the voltage reading should be reference voltage (48V, the battery should be fully

charged).

9.3 If the voltage reading is 0V when the accelerator pedal is depressed, check the pedal switch

circuit in the following procedures.

9.3.1 Use a multimeter set at 200V DC, connect the black (-) probe to the negative binding post

of Battery 6 and connect the red (+) probe to the pedal switch output wire (Wire 1). Turn

on the key switch, the reading should be around 48V (the battery is fully charged).

9.3.2 If the reading is 0V, check the red wire between the key switch and the accelerator for

continuity, if it is ok, check the accelerator pedal switch for continuity. If the continuity of

pedal switch is checked with an unsatisfactory result, replace the accelerator.

Troubleshooting

MERGE 10-7

Chapter 10

Check Procedure 7--Controller signal

Check Procedure 7A—Pin 1

1 Use a multimeter set at 200V DC, insert the red (+) probe of the multimeter into Pin 1 (red wire).

Refer to the following Note. Connect the black (-) probe to the negative binding post of the battery

pack.

2 Turn Tow/Run switch to RUN, then the multimeter should display a full battery voltage (about 48V).

3 If another reading is displayed, the following items must be checked:

• Continuity of wires in harness;

• Check whether Tow/Run switch operates normally. Refer to “Check Procedure 4 - TOW/RUN

switch”

! NOTE:

• Never insert the complete probe into the 9-wire plug for fear of poor contact.

9-wire connector of controller plug Function

(Pin 1)-red wire Battery - positive electrode

(Pin 2)- yellow wire Input signal of motor speed sensor - a pulse input signal

provided to controller by motor speed sensor.

(Pin 4) - black/yellow wire

FORWARD input signal provided by Forward/Reverse

switch--when Forward/Reverse switch is on FORWARD

position, the switch provides a voltage of +48V to the

controller.

(Pin 5) - blue/white wire

REVERSE input signal provided by Forward/Reverse

switch--when Forward/Reverse switch is on REVERSE

position, the switch provides a voltage of +48V to the

controller.

(Pin 7) - black/white wireAn input signal of 0-4.6V provided to the controller by

accelerator

(Pin 6) - red/green wireKey switch input signal--when the key switch is ON, the switch

provides a voltage of +48V to the controller.

(Pin 3)-pink wire

Pedal switch – when the accelerator pedal is depressed, the

accelerator limit switch provide a voltage of +48V to the

controller.

(Pin 10) - brown/yellow wireBuzzer output signal - output signal provided to reverse

buzzer by controller.

(Pin 14)-light green wire Mode switch signal, provide two types of mode conversion

Troubleshooting

MERGE 10-8

Chapter 10

Check Procedure 7B—Pin 4 and 5


Pin 4 and 5 of the 9-wire connector are designed to connect Forward/Reverse switch and the controller.

When Forward/Reverse switch is on FORWARD position, the switch sends a +48V signal to the

controller through Pin 4; when Forward/Reverse switch is on REVERSE position, the switch sends a

+48V signal to the controller through Pin 5.

1. Use a multimeter set at 200V DC, insert the red (+) probe of the multimeter into Pin 4 (black/yellow

wire).Refer to the following Note. Connect the black (-) probe to the negative binding post of the

battery pack.

! Note:


2. When Tow /Run switch is turned on RUN and Forward/Reverse switch is on NEUTRAL, the

multimeter should display a 0V DC voltage.

3. While observing the multimeter, turn the Forward/Reverse switch to REVERSE. The multimeter

should display a voltage of +48V.

4. Turn Forward/Reverse switch to FORWARD, the multimeter should display a full battery voltage

(about 48V).

5. Insert the red (+) probe of the multimeter into Pin 5 (blue/black wire) of the 9-wire connector. Leave

the black (-) probe connected to the negative binding post of the battery pack. Refer to the above

Note.

6. Turn the Forward/Reverse switch to NEUTRAL. Now, the multimeter should display a 0V DC

voltage.

7. While observing the multimeter, turn Forward/Reverse switch to FORWARD, the multimeter should

display a voltage of +48V.

8. Turn Forward/Reverse switch to REVERSE, the multimeter should display a full battery voltage

(about 48V).

9. If another reading is displayed, the following items must be checked:


• Whether Forward/Reverse switch operates normally. Refer to “Check Procedure

10—Forward/Reverse gear switch”.


switch”.

Troubleshooting

MERGE 10-9

Chapter 10

Check Procedure 7C—Pin 7

1. Use a multimeter set at 200V DC, insert the red (+) probe of the multimeter into Pin 7 (pink wire).

Refer to the following Note. Connect the black (-) probe to the negative binding post of the battery

pack.

! Note:


2. When Tow/Run switch is turned on RUN and Forward/Reverse switch is on NEUTRAL, the


3. Depress the accelerator pedal slowly, the multimeter voltage should change from 0V to 4.6-5V.

4. If multimeter voltage does not change, the following items must be checked:

4.1 Continuity of wires in harness;

4.2 If the continuity is ok, please check whether the handle brake switch is connected and the wire

connection is correct, if it is abnormal replace the accelerator.

Check Procedure 7D—Pin 6

1. Use a multimeter set at 200V DC, insert the red (+) probe of the multimeter into Pin 6 (red/green

wire). Refer to the following Note. Connect the black (-) probe to the negative binding post of the

battery pack.

2. With key switch turned ON, turn Tow/Run switch to RUN, then the multimeter should display a full

battery voltage (about 48V).

! NOTE:


3. If another reading is displayed, the following items must be checked:


• Check whether the key switch operates normally;


switch” on page 25.

Check Procedure 7E—Pin 3

1. Use a multimeter set at 200V DC, insert the red (+) probe of the multimeter into Pin 3 (magenta

wire). Refer to the following Note. Connect the black (-) probe to the negative binding post of the

battery pack.

Troubleshooting

MERGE 10-10

Chapter 10

! Note:


2. When Tow/Run switch is turned on RUN and Forward/Reverse switch is on NEUTRAL, the


3. Depress the accelerator pedal, the multimeter should display the full battery voltage (about 48V).

4. If multimeter voltage does not change, the following items must be checked:


• If the continuity is ok, replace the accelerator pedal switch. Refer to “Check Procedure 6—Circuit

check for key switch and accelerator pedal switch”.

Check Procedure 8—Motor speed sensor


! NOTE:

• The following operations must be conducted on a flat surface. To prevent injury or property

loss, make sure that the passage of the electric vehicle is unblocked before moving it.

1. Turn the key switch to OFF and turn Forward/Reverse gear switch to NEUTRAL.

2. Use a multimeter set to 200V DC, connect the red (+) probe to the positive binding post of the

battery and connect the black (-) probe to the Terminal 16 of the 3-wire connector. The voltage

reading should be approximately 0V (the battery is fully charged).

3. Turn Tow/Run switch to RUN, use a multimeter set to 20V DC, connect the black (-) probe to the

negative binding post of the battery pack and connect the red (+) probe to red wire of the 3-wire

connector. The voltage reading should be approximately 12V.

4. If the reading is 0V, check the continuity of red wire of 3-wire connector which connects the

controller and the motor speed sensor. If the continuity is ok, replace the controller.

5. If the voltage reading is correct, continue with the following operations:

5.1 Use a multimeter set to 20V DC, connect the black (-) probe to the negative binding post of the

battery pack and connect the red (+) probe to the terminal of green wire of the 3-wire connector

on the motor speed sensor. The voltage reading should be approximately 4.60-5.00V.

5.2 If the reading is 0V, check the continuity of green wire of 3-wire connector which connects the

controller and the motor speed sensor. If the continuity is ok, replace the controller.

5.3 If the reading is lower than 3.50V, check the wire and plug for continuity and replace the

controller if necessary.

Troubleshooting

MERGE 10-11

Chapter 10

6. Reconnect the 3-wire connector on the motor speed sensor. Use a multimeter set to 20V DC,

connect the black (-) probe to the negative binding post of the battery pack and connect the red (+)

probe to green wire which is between the 3-wire connector on the motor speed sensor.

6.1 Jack up a rear wheel so that it is off the ground. Turn the rear wheel slowly drive the armature

of the motor. When the armature is rotating, the voltage reading should change from 0V to

approximately 4.85V. In each round the motor armature rotates, the voltage reading will change

from 0V to 4.85V and 0V for 4 times.

NOTE: 4.85V is a approximate reading of voltage. The actual reading may range between 4.50V

and 5.00V.

6.2 The speed sensor should be replaced in the following cases:

• No voltage reading is displayed;

• The voltage reading is no greater than 3.50V;

• No voltage reading change when the motor is running.

Check Procedure 9—forward/reverse gear switch




2. Disconnect the 3 wires from the gear switch. Use a multimeter set at 200!,connect the black (-)

probe to Position 7 (or 8) of the gear switch, then connect the red (+) probe to Position 3 (or 4).

When the switch is on NEUTRAL or REVERSE, no continuity should be indicated. When the switch

is on FORWARD, continuity should be indicated. If the reading is not correct, replace the switch.

3. Connect the black (-) probe to Position 1 (or 2) of the gear switch, then connect the red (+) probe to

Position 3 (or 4). When the switch is on NEUTRAL or FORWARD, no continuity should be indicated.

When the switch is on REVERSE, continuity should be indicated. If the reading is not correct,

replace the switch.

Check Procedure 10—Reverse buzzer



2. Remove screws on each side of the instrument panel

3. Pull out the instrument panel along the driving handle.

4. Disconnect the brown/yellow wire and the red wire from the reverse buzzer. Make sure that the

terminal on the key switch will contact the frame.

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Chapter 10

5. Turn Tow/Run switch to RUN.

6. When the battery is connected, use a multimeter set at 200V DC, connect the black (-) probe to the

negative binding post of Battery 6 and connect the red (+) probe to the disconnected red terminal of

the reverse buzzer. The voltage reading should be approximately 48V (the battery is fully charged).

7. If the voltage reading is correct, go to Step 12.

8. If the reading is 0, check the continuity of the red wire and Tow/Run switch. Refer to “Check

Procedure 4 - TOW/RUN switch”.

9. If the continuity reading is not correct, repair or replace the red wire.

10. If the continuity reading is correct, continue with the following operations.

11. Turn Forward/Reverse gear switch to REVERSE position. Use a multimeter set to 200V DC,

connect the red (+) probe to the positive binding post of Battery 1 and connect the black (-) probe

to the brown/yellow wire of the output line of the buzzer. The voltage reading should be

approximately 43V.

12. If the reading 0V, check the brown/yellow wire for continuity and the connection of Pin P10 of the

9-wire connector.

13. In case of un-continuity of the brown/yellow wire or improperly arranged Pin 10 of the controller,

repair or replace the part as required.

Check Procedure 11 -- Battery discharge meter


The main cable has three wires connected to the battery discharge meter: red wire (connected to

Tow/Run switch), red/green wire (connected to key switch) and black wire (connected to the negative

terminal of the battery pack).

Check as follows with a multimeter:

1. Turn Tow/Run switch to RUN, use a multimeter set to 200V DC, connect the red (+) probe to the red

wire and connect the black (-) probe to the negative binding post of Battery 6. The voltage reading

should be 48V. If the voltage is 0V, check the continuity of the red wire and Tow/Run switch.

2. Turn Tow/Run switch to RUN and turn the key switch to ON, use a multimeter set to 200V DC,

connect the red (+) probe to the red/green wire and connect the black (-) probe to the negative

binding post of Battery 6. The voltage reading should be 48V. If the voltage is 0V, check the

continuity of the red/green wire and key switch.

3. Check the continuity of the black wire and the battery pack.

If the three wires are ok and the battery discharge meter displays nothing, replace the battery

discharge meter.

Troubleshooting

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Chapter 10

Check Procedure 12-- High mount stop lamp


With Tow/Run switch on RUN and key switch ON, check the high mount stop lamp interface on main

cable with a multimeter set at 200V DC (connect the red probe to green/yellow wire and connect the

black probe to black wire) while depressing the brake pedal. The voltage should be 12V. Perform the

following checks if the voltage is 0:

1. Check whether the DC converter outputs a 12V voltage. Check the converter for failure and replace

it if necessary. Continue with Step 2 if it is ok.

2. Check the fuse in the fuse box and replace it if necessary. If the fuse is ok, go to Step 3.

3. Check the brake switch for normal operation.

4. If everything is ok and the measured voltage is still 0, replace the main cable.

Check Procedure 13 - wiper


With Tow/Run switch on RUN and key switch ON, check the wire connected to the wiper of main cable

with a multimeter set at 200V DC (connect the red probe to yellow/blue wire and connect the black probe

to black wire). The voltage should be 12V. Perform the following checks if the voltage is 0:




3. If no problem is found in the above Step 1 and 2 and there is no 12V output, replace the wiper

harness.

4. If the above checks are satisfactory (ie. there is a 12V output), connect the wiper interface to the

main cable and turn on the wiper switch to check the wiper for normal operation, replace the wiper if

it does not operate.

Check Procedure 14— flashing light


With Tow/Run switch on RUN and key switch ON, check the wire connected to the flashing light of main

cable with a multimeter set at 200V DC (connect the red probe to yellow/blue wire and connect the black

probe to black wire). The voltage should be 12V. Perform the following checks if the voltage is 0:




Troubleshooting

MERGE 10-14

Chapter 10

3. If no problem is found in the above Step 1 and 2 and there is no 12V output, replace the main cable.

4. If the above checks are satisfactory (ie. there is a 12V output), connect the flashing light interface to

the main cable to check the flashing light for normal operation, replace the flashing light if it does not

operate normally.

Troubleshooting Instructions Part 2 (controller failure indication code):

CURTIS1268 controller There is two methods to make diagnosis: one is hand holder programmer,

have a troubleshooting the source of range through the indication code on controller; another is get the

troubleshooting information from the LED indicator on the controller.

Programmer diagnosis

The programmer express full of trouble shooting information with brief work, it was showed on the

manual, the input/output status was showed on the testing manual.

The history manual of diagnosis provides all the troubleshooting list after last clean of history

manual, we suggest you check and clean all troubleshooting history file when you do the maintenance

each time.

For example: if the car can not move forward, the way of repairing will be:

1. There is no failure on the cable connection, such as: disconnect or loosen

2. Connect the programmer, choose diagnosing manual, see the display on it, if it says: NO

KNOW FAULTS then it means everything is OK

3. Choose testing manual, observe the input/output status for forward, if the “FORWARD

INPUT” is OFF on the testing manual, then there is some failure on the forward switch or the

switch cable connection.

4. Check or replace the cable of forward switch. Test it again, if the programmer displays the

forward switch is ON and the car is workable then it means the problem has been solved.

Controller failure indication code

NO. LCD display on programmer Meaning Reasons

1 THROTTLE FAULT 1 The sliding signal of

accelerator is out of range

1 The input cable of the

throttle is open

2 Throttle cable is short circuit

to B+ or B-

2LOW BATTERY

VOLTAGE Low voltage in the battery

1 Cut off due to lower voltage

2 The end of battery

connection is corrosive

3 The terminal of battery or

controller is loose

3 OVER VOLTAGE Over voltage

1 Cut off due to lower voltage

2 Charge battery during it work

3 Battery is off when you apply

for brake

4 THERMAL CUTBACK Cut off due to higher/lower

temperature

1 Temperature is over 85 or

less than-25

2 Over loaded

3 The installation of controller

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MERGE 10-15

Chapter 10

is not fit

4 The extreme work condition

5 HPD HPD failure

1 The order of direction and

throttle is wrong

2 Choose wrong HPD type

3 Wrong adjustment on the

throttle potentiometer

4 Order delay is too short

6 RELAY COIL FAULT Time-delay coil failure 1 wrong connection on the

time-delay coil

7 RELAY DRIVER OFF Time-delay coil over

currency

1 short circuit on the time-delay

coil

8 RELAY DRIVER ON Time-delay coil less

currency

1 time-delay coil is off or

damaged

9 CIRCUIT BRKR OPEN Antislip circuit is open circuit

or fuse is damage

1 Fuse is broken

2 Antislip circuit failure

3 Speed sensor failure

10 MAIN WELDED Main contactor welded

1 Main contactor is welded

2 The drive of main contactor

is short

11 WELDED AUX CONT Auxiliary contactor welded

1 Auxiliary contactor is welded

2 The drive of auxiliary

contactor is short

12 SPEED SENSOR FAULT Speed sensor failure

1 No connection on the speed

sensor

2 Speed sensor is broken

13 MAIN DRIVER ON The drive input of main

contactor is less currency

1 Main contactor failure or

open circuit

2 controller is broken

14 MAIN COIL FAULT The coil of main contactor is

failure

1 The coil of main contactor is

open or disconnect

15 MAIN DROPOUT Main contactor is open 1 main contactor is broken

16 MOTOR STALL Motor failure

1 incorrect installation of the

motor

2 Motor stall

3 EM brake cable is fault

4 Speed sensor is broken

17 MAIN DRIVER OFF Driving output on main

contactor is over currency

1 Main contactor failure or coil

is short circuit.

2 Controller is broken

18 AUX CONT DN Auxiliary contactor is open 1 the driving of auxiliary

contactor is short circuit

19 KEY SWITCH SRO Key switch SRO failure 1 Interlock on the key switch

and the order delay is wrong

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Chapter 10

2 Choose wont type of SRO

3 Interlock or direction switch

is open circuit

4 Order delay is too short

20 CURRENT SENSE FAULT Excitation currency sensor

failure

1 controller is broken

21 M- SHORTED Inner M-is short circuit to B- 1 controller is broken

2215 VOLT FAULT 15V voltage is out of range


2 Seton of exterior circuit

23DRIVER OVERCURRENT

Over currency on main

contactor or auxiliary one

1 main contactor or auxiliary

contactor is short circuit

24

PRECHARGE FAULT Inner voltage is too low

during start


2 Out B- is short to B+ or leak

power

25FIELD MISSING Excitation damage

1 Motor field cable come off

2 Motor field cable is open

26 HW FAILSAFE Automatic checking failure 1 controller is broken

Picture 1 1268 controller programmer faulty code table

LED failure diagnosis

There is LED on the controller you can see it from the window on the top of controller cover.

When there is any fault on the controller or the input then it will display the failure indication code.

When it work , the LED will flicker steadily; if it inspect some failure, the dibit indicator will keep

flickering until the trouble was eliminated. Such as if the code“3 2” main contactor is welded, it

display as below.

¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤

(3,2) (3,2) (3,2)

Code list

LED code symbol description

LED all off No power or the controller was broken

All on ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ Problem one the micro processor in the

controller

1,1 ¤ ¤ Controller was broken

1,2 ¤ ¤¤ The sliding signal of accelerator is

outside the scope

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Chapter 10

1,3 ¤ ¤¤¤ Speed sensor failure

1,4 ¤ ¤¤¤¤ HPD failure

1,5 ¤ ¤¤¤¤¤ Motor failure

2,1 ¤¤ ¤ Low voltage in the battery

2,2 ¤¤ ¤¤ Over voltage

2,3 ¤¤ ¤¤¤ Over/less temperature off

2,4 ¤¤ ¤¤¤¤ Lack of currency on the driving output in

the main contactor

2,5 ¤¤ ¤¤¤¤¤ Auxiliary contactor is open

3,1 ¤¤¤ ¤ Driving input of main contactor is over

currency

3,2 ¤¤¤ ¤¤ Main contactor is weled

3,3 ¤¤¤ ¤¤¤ The inner voltage is too low during start

3,4 ¤¤¤ ¤¤¤¤ Excitation damage

3,5 ¤¤¤ ¤¤¤¤¤ Auxiliary contactor is over currency

4,1 ¤¤¤¤ ¤ Field currency speed sensor is failure

4,2 ¤¤¤¤ ¤¤ The driving of main contactor or auxiliary

is over currency

4,3 ¤¤¤¤ ¤¤¤ Inner M-is short circuit to B-

4,4 ¤¤¤¤ ¤¤¤¤ The auxiliary is delay of close

4,5 ¤¤¤¤ ¤¤¤¤¤ Auxiliary contactor is delay of weled

5,1 ¤¤¤¤¤ ¤ Key switch SRO failure

5,2 ¤¤¤¤¤ ¤¤ The coil of main contactor is open

5,3 ¤¤¤¤¤ ¤¤¤ Less currency on the coil

5,4 ¤¤¤¤¤ ¤¤¤¤ antislip circuit failure or antislip fuse is

open circuit

5,5 ¤¤¤¤¤ ¤¤¤¤¤ Main contactor is open

Picture 2. 1268 controller LED diagnosis table

Note: one time only display one failure, the failures are not in order. If there is some mistake on the

SRO, you could eliminate it by converting the lock switch or key switch.

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Chapter 11

Battery

Overview

The battery provided for the electric vehicle must be able to provide all (100%) the energy it requires.

Therefore, the battery will make a deep discharge of 70% to 80% of its full capacity before being

recharged, which is a process named “deep cycle”. Notwithstanding the great discrepancy of current

intensity of different vehicles in varied operation modes, the average current intensity on the 48V electric

vehicle is 75A. The deep cycle battery is specially designed for this purpose.

The chargeable lead-acid battery can translate the chemical energy into electrical energy and vice versa.

The major active elements in the battery are positive plate, negative plate and electrolyte (sulfuric acid).

Another important element (not active) is partition. The partition is verifiably an element that separates

the positive plate and negative plate and prevents their contact. Their contact will result in the short

circuit. The partition has sufficient holes to allow the passage of charged ions through positive and

negative plates while preventing the contact of the plates.

Two different metals that are immersed into one acid can generate the electric current. In the deep cycle

battery, the negative plate contains plum bum (Pb), and the positive plate contains lead dioxide. These

plates are immersed in the sulfuric acid solution (H2SO4) (see Fig 11-1).

During the discharge, the chemical reaction in the battery will result in the departure of sulfate ion (SO4)

from H2 (see Fig 11-2).

The sulfate ion (SO4) and the plum bum (Pb) on the two plates together form lead sulfate (PbSO4). The

oxygen from the positive plate (O2) and the hydrogen from the electrolyte (H) form water (H2O) (see Fig

11-3).

Fig 11-1: Schematic diagram of charged battery Fig 11-2: Discharging battery

Electric motor

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Chapter 11

The result is two metalloids, the lead sulfate (PbSO4) immerse in water (H2O). As the battery is fully

discharged, no electric energy can be generated.

After the connection of discharged battery and the charger, in the reverse procedures, the sulfate ion

(SO4) enters the electrolyte from the positive and negative plates to form sulfuric acid (H2SO4). The

oxygen returns to the positive plate to form lead dioxide (PbO2) (see Fig 11-4).

The result is the chargeable battery that can re-generate the electrical energy.

Fig 11-3: Discharged battery Fig 11-4: Charging battery

Common misconceptions about battery

Common misconceptions about the deep cycle battery of electric vehicle and the maintenance of the

battery are shown in the table below.

Problems Misconceptions Actual states

Deep discharge

“The electric vehicle runs slowly,

but we still can have it run until it

has no electrical energy.”

Try to avoid the deep discharge

of battery. Please refer to “deep

discharge ”.

Premature excessive discharge

“These are new batteries.

Therefore they can supply

power all day long.”

The new battery cannot reach

its full capacity until being used

and charged for twenty to fifty

times. Please refer to

“premature excessive

discharge”.

Mineral content “Our batteries can use tap

water.”

Your tap water may be OK, but

inspection before hand is

required. Please refer to

“mineral content”.

Charger

Battery and Charger

MERGE 11-3

Chapter 11

Self discharge “The dirt and rust on the battery

will do no harm.”

The dirt and rust may form

current passage, which results

in the self discharge of battery.

Please refer to “self discharge”.

Over-watering

“Fill water into the battery to the

liquid level in the evening.

Therefore, water filling is not

necessary in the morning.”

In most cases, water must be

filled into the battery after

charging. Please refer to “liquid

level of electrolyte”.

Under-watering

“It takes too much time to

inspect the water, and the

inspection can be made one a

month.”

Under-watering is harmful to the

battery. The water level should

be inspected once a week.

Please refer to “liquid level of

electrolyte”.

Vibration damage

“The user should secure the

battery hold-down gear to the

best possible degree.”

The user should secure the

hold-down gear of the battery

following the instructions. Too

tight or too loose hold-down

gear will result in the damage of

the battery. Please refer to

“vibration damage”.

Battery replacement

! WARNING

• The battery must be handled by special lifting tools. To prevent the electrolyte from leaking

out of the battery air bleeders, the battery must remain upright. Inclination of over

45°towards any direction may result in the leakage of small amount of electrolyte from the air

bleeder. The inclination of the battery should not exceed 45°when being lifted, carried or

mounted. The battery acid may result in serious personal injury to the skin or eyes, and may

also damage the clothes.

1. Before removing the battery, please note the orientation of the battery and connecting line.

Disconnect the battery cable according to the instructions. Please refer to Chapter 1 “Protection for

Electrical Safety”. Remove the remaining wires and battery. Please refer to the wiring diagram on

page 9-7.

2. Visually inspect the new battery for damage in transit.

3. The original battery cable, if to be used again, should be inspected for rupture or abrasion. In

addition, its terminals should be inspected for damage, or the insulating layer for aging. Please

erase the rust and dirt on the connector. The solution of sodium bicarbonate and water (a gallon

(3.8L) of water is mixed with a glass (237mL) of sodium bicarbonate) can effectively neutralize and

erase the rusty stain. Care should be taken to avoid the sodium bicarbonate solution from entering

the battery.

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MERGE 11-4

Chapter 11

Fig 11-5: Schematic diagram of electric vehicle battery

4. Inspect and clean the battery support and hold-down gear. The nuts and bolts on the hold-down

gear may rust. Therefore, it is suggested that they are cleaned on a regular basis, and be replaced

when necessary.

5. Mount the battery in the right direction (see Fig 11-5). Mount the battery hold-down gear. The

hold-down gear must be sufficiently tight to secure the battery when the electric vehicle is in

operation to such a degree that the battery enclosure is not cracked or bent. Tighten the hold-down

bolts with 40 in-lb (4.5N m) torque.

6. Mount the wires in the right order (see Fig 11-5). At last, connect the negative terminal of the battery

pack. Ensure all the wires are in good connection. Tighten with 110 in-lb (12.4N m) torque. Apply

terminal protection oil to all connecting terminals to minimize the potential corrosion.

7. Fully charge the battery before use. In this way, the battery can be ensured to have been fully

charged before use, and the electric quantity of the battery compartment is balanced.

Battery maintenance

Preventative maintenance

To maintain the battery in good working order, please take the following procedures regularly:

1. The rust and dirt on or around the battery should be cleaned immediately. The terminal joints should

be cleaned and secured. Replace the aged or worn wires. Apply the terminal protection oil to all the

connecting terminals after all cables are connected to prevent future corrosion.

2. The battery should remain clean and rust-free. Clean the battery top and connecting terminal with

sodium bicarbonate and water solution (one gallon (3.8L) water is mixed with 1 glass (237mL) of

sodium bicarbonate). Clean the solution with fresh water. The solution should be prevented from

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Chapter 11

entering the battery. Ensure the connecting terminals are tightly secured. When all terminals are

dried, apply the terminal protection oil to all the connecting terminals. Please refer to “self

discharge”.

3. Maintain the electrolyte at normal liquid level. Please refer to “electrolyte liquid level”.

4. The battery should be charged every day after it is used. Inspect the battery periodically to ensure

that the battery is fully charged. Please refer to “battery charging”.

5. Tighten the hold-down gear. Please refer to “vibration damage”.

Self discharge

The dirt on the battery may form weak battery passage, which may result in slow discharge of the battery

and therefore waste the precious electrical energy. To avoid self discharge, the battery should remain

clean all the time.

The temperature also has influences on the speed of self discharge by the battery. The higher the

temperature is, the quicker a set of battery is discharged. In hot regions, the battery should be inspected

more frequently. The battery should be stored in shady and cool places. Please refer to “storage of

battery”.

Electrolyte liquid level

! NOTICE

• The battery acid exuded from the battery cover or hydrometer should be prevented from

dropping onto the front or rear body of the electric vehicle. Battery acid may result in

irremediable defect, and should be cleaned up immediately.

Fig 11-6: Liquid level of battery solution

Water is filled only when the liquid level of electrolyte is lower than the height of positive and negative

plates. In case the liquid level of electrolyte is lower than the height of positive and negative plates,

please fill enough water to cover the plates before charging the battery. After charging, re-fill the water to

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Chapter 11

liquid level benchmark. This is because the liquid level of electrolyte may rise when the battery is

charged. Some electrolyte may burst out of the battery cover. Therefore, filling water to the liquid level

before battery charging may result in the spillage. This will reduce the battery capacity and corrode its

neighboring metal components.

The electrolyte liquid level should be inspected once a week to ensure that the electrolyte is maintained

at the normal liquid level (see Fig 11-6). Never allow the electrolyte be lower than the top of the positive

and negative plates, as this will result in the permanent inertia of exposed plates. To achieve the

optimum result, please fill water into the battery with watering gun. In hot weather or when the battery

becomes aged, the liquid level of electrolyte should be inspected more frequently.

Mineral content

To prolong battery life to the longest possible degree, the battery should be filled with distilled water. In

case tap water is to be used, the water must be ensured to contain minerals of which the contents are

below the level specified below:

Impurities Allowable content (ppm)

Suspended

substanceCannot be viewed visibly

Total solid 100.0

Calcium and

magnesium oxides 40.0

Iron 5.0

Ammonia 8.0

Organic matter 50.0

Nitrate 10.0

Nitrite 5.0

Chloride 5.0

Vibration damage

The battery hold-down gear should remain tight and secure to prevent the battery from jumping out. In

case the battery hold-down gear is too loose, the service life of the battery may be shortened to a great

extent. Secure the hold-down gear with a load of 40 in-lb (4.5 N m). With too strong vibration, the

positive and negative plates may come off prematurely and the battery life may be shortened. It may also

result in the leakage of acid fluid from air bleeder cover and in the accumulation of rust and dirt on the

neighboring metal components. The lost acid fluid may reduce the battery capacity and cannot be

replaced. However, the battery hold-down gear shouldn't be too tight, so as to prevent the battery

enclosure from being fractured or bent. This will result in leakage, and further to the dry-up of the battery

compartment or short circuit. Please refer to Chapter 1 “Protection for Electrical Safety”.

Battery and Charger

MERGE 11-7

Chapter 11

Battery charging

The charger provided for the E-merge electric vehicle has brought a solution to the common problem

relating to the battery charging. The charger can shut off automatically to prevent undercharge and

overcharge. Meanwhile, all battery compartments are automatically distributed with balanced electric

quantity by the light current in such a way to prolong the service life of the battery. Never allow the

battery to be in the discharge condition, as it may affect the internal components and reduce the battery

capacity. The battery should be charged every day after it is used. In case the battery is not used, no

charging is required.

In case any of the following situations: 1 new battery; 2 long-term use; 3 the humidity is too low,

additional charge may be required. The electric quantity of battery of electric vehicles that are not in

operation should be inspected. The battery of which the specific gravity is less than 1.250 requires

additional charge. In case the problem still remains unsettled after the additional charge, the charger of

the battery should be inspected. Please refer to “battery charger”.

Deep discharge

It is strictly prohibited to charge the battery until it has no enough power to drive the vehicle. This may

shorten the cycle life of the battery remarkably, and may result in the irremediable defect of the battery.

In case the battery is fully discharged, it may be unable to be charged any longer. To more the battery is

discharged, the harder the battery is able to bear. Therefore, it is suggested that every time the battery is

used (in case the charging cycle is not interrupted and the charger can shut off automatically), the

electric vehicle is charged. Charging the battery every time it is used can diminish the discharge depth

and prolong the service life of the battery.

Premature excessive discharge

In case the new battery is used, it will not reach its full capacity before it is used and charged for 20 to 50

times. IN case the new battery is over-discharged during its service life, its effective service life will be

shortened, and it is therefore suggested that the use of electric vehicle in the first four weeks is restricted

before it will be used for wider ranges.

AC power supply line

Ensure that the power supply line providing the alternating current has adequate capacity. In case the

breaker trips, the fuse is burnt at night or the charger fails to reach the required starting velocity when it

charges the normal battery, the problem may lie with the AC power line. When all charges are open, the

power supply line of the storage facility of the electric vehicle can supply sufficient voltage and current for

each charger. In case it fails to do so, please consult with the local power company or electricity

inspector. Please refer to “battery charger”.

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Chapter 11

Alternating use of vehicles

Use the electric vehicles alternately. In case the vehicle came back the last yesterday evening is dispatched

as the first one the next morning, its battery is hard to sustain. The workload should be equally allocated so

that all electric vehicles are equally used. This can balance the use of vehicles and prevent the overwork of

some batteries.

Electric vehicle and charger numbering

If possible, the electric vehicle is desirable to be charged by one and the same charger every night. In

case the electric vehicles are stored in the garage at random, and one of the vehicles breaks down

during operation and the inspection shows that the battery is normal, the cause may very likely be the

abnormality of the charger. However, it is time-consuming to detect the problematic charger. Number the

vehicle and the charger, and drive the vehicle to the designated charger, which can greatly reduce the

time spent on detection of the problematic charger.

Battery and Charger

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Chapter 11

Battery troubleshooting diagram

Fig 11-7: Battery troubleshooting diagram

The vehicle performance falls short of expectation

Fully charge the battery

Inspect and test the battery charger

The reading is lower than 6A and the

charging voltage is higher than 56V.

The reading is not lower than 6A.

Charging voltage inspection

Inspect the electrical system and the charger for

defects. Please refer to “troubleshooting guide”.

In case no problem is identified, please proceed

with the charging voltage inspection.

All the readings are lower than 9.3V, but the

difference of any two readings doesn’t exceed 0.7V

In case the reading of any single battery is lower

than 9.3V, and its difference with the battery that has

a voltage of over 9.3V exceeds 0.7V, the battery

should be replaced.

All the readings are higher than 9.3V, but the

difference of any two readings doesn’t exceed 0.7V

It may be used battery. Carry out hydrometer test. Hydrometer test

Replace the battery that the specific gravity of two

batteries exceeds 50 or has no readings.

The whole set of battery of which the specific

gravity reading is lower than 1.250 is usually

undercharged. Evaluate charging operation.

No remarkable problem

Discharge inspection

In case the discharge time is shorter than 60

minutes, all batteries are lower than 6.7V.

In case the discharge time is not shorter than 60

minutes, the problem is not with battery.

Battery and Charger

MERGE 11-10

Chapter 11

Inspection and test of the battery


Carry out four inspections to find out the cause to the battery performance reduction. As these

inspections are more and more detail and time-consuming, please carry out the inspection from the

beginning before proceeding to other inspections until the problem is identified as shown in “battery

troubleshooting diagram” (see Fig 11-7).

Inspection and test of the battery charger

The easiest way to monitor the battery of the vehicle is to observe the reading on the ampere-meter of

the battery charger on completion of one charge cycle. When the battery is fully charged, unplug the DC

connector of the charger and wait for 20-30 seconds before reconnecting the DC connector of the

charger. The pointer of the ammeter will jump to over 15A, and then drop below 6A in 10 to 20 minutes,

which means the battery is normal and fully charged. In case the performance is still poor, the problem

may lie with the electrical system, braking system or the battery charger of the vehicle. In case no

problem is identified from the electric vehicle or the charging system, inspection of the additional voltage

should be made. The battery of over 8V should also go through charging voltage inspection.

Charging voltage inspection

When the battery is fully charged, unplug the DC connector of the charger. Wait for 20-30 seconds

before reconnecting the DC connector to restart the charger. Five minutes later, measure and record the

voltage of the battery pack and of each battery with the multimeter. Set the multimeter at 200V DC.

Attach the red ( ) probe to the positive ( ) terminal of No.1 battery, and attach the black (-) probe to

the negative (-) terminal of the battery pack (see Fig 11-5). Take down the reading. Then set the

multimeter at 20V DC. Attach the red ( ) probe to the positive ( ) terminals of all batteries, and attach

the black (-) probe to the negative (-) terminals of all batteries. Take down the reading. The charged

battery of the battery pack should have a voltage between 56.0-63.0V, which is subject to the years it is

used and the electric quantity of the inspected battery. In case the reading of a single battery is higher

than 9.3V, and the difference of readings do not exceed 0.7V, the inspection by hydrometer should be

conducted. In case the reading of any single battery is lower than 9.3V, and its difference with the battery

that has a voltage of over 9.3V exceeds 0.7V, the battery should be replaced. In case the reading of any

single battery is lower than 9.3V, but its difference with other reading does not exceed 0.7V, it means the

battery is too old. The capacity of the old battery may be able to sustain for a few months. Inspection with

the hydrometer shall be conducted.

Inspection with hydrometer

The specific gravity of the battery electrolyte can be measured by the hydrometer. The higher the

specific gravity is, the more electric quantity the battery has. When the temperature is 80 (26.7 ),

the reading of the fully charged battery should range between 1.250 and 1.280. Never increase the

specific gravity by means of filling acidic fluid into the battery.

Battery and Charger

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Chapter 11

Procedures for inspection with hydrometer

1. Before inspection, first ensure that the battery has sufficient electrolyte to cover the electrode plates

by about 1/2 inch (13mm) and is fully charged. In case it is a must to fill water, the batter should be

recharged before the inspection with hydrometer.

2. Remove the air bleeder cover. Measure with the thermometer and take down the electrolyte

temperature at Battery Compartment No.2.

3. Extrude the rubber bag of the hydrometer before inserting the battery compartment. Release the

rubber bag slowly so that the electrolyte is sucked into the glass tube of hydrometer.

4. Adjust the liquid level of the electrolyte when the buoy floats above the bottom to such a degree that

the buoy is in neither contact with the bottom nor the top of the glass tube. Take down the

hydrometer from the battery compartment before releasing the pressure of the rubber bag.

5. Take hold of the hydrometer vertically so that the buoy will not touch the sidewall. Raise the hydrometer

to the height the same as the eyes and observe the scale value of the liquid level of electrolyte (see Fig

11-8).

6. Take down the reading and enable the electrolyte in the hydrometer to return back to the battery

compartment. Replace the air bleeder cover.

7. Repeat Step 2-6 to all battery compartments.

Calibration of hydrometer

Most of the hydrometers are calibrated and can perform precise measurement under 80 (26.7 ). The

above observed readings should be corrected according to the temperature. Every increase of 10

(5.6 ) over 80 (26.7 ) should result in the addition of 0.004 to the reading. Every decrease of 10

(5.6 ) below 80 (26.7 ) should result in the subtraction of 0.004 from the reading.

Hydrometer inspection result presentation

The table below shows the rough electric quantity the charged battery has:

Specific gravity (corrected

with the temperature) Rough charging condition

1.250-1.280 100%

1.220-1.240 75%

1.190-1.210 50%

1.160-1.180 25%

In case the difference between batteries is not less than 0.020, the problem may lie with the battery

compartment with relatively lower specific gravity. It may need additional charge or may be light current

battery. In case the difference between batteries is not less than 0.050, the battery with relatively low

specific gravity should be replaced.

Battery and Charger

MERGE 11-12

Chapter 11

Fig 11-8: Hydrometer

Corrected specific gravity Vehicle

number

Battery

number

Electrolyte

temperature

Correction

factor Battery 1 Battery 2 Battery 3 Battery 4

Measures

should be

taken

12 1 20°F (-6.6°C) –.024 1.275 –.024

=1.251

1.280 –.024

=1.256

1.280 –.024

=1.256

1.280 –.024

=1.256

Normal

battery-fully

charged

35 6 90°F (32.2°C) +.004 1.155+ .004

=1.159

1.165+ .004

=1.169

1.160+ .004

=1.164

1.165 –.004

=1.169

Discharged

battery-charge

54 3 50°F (10°C) –.012 1.260 –.012

=1.248

1.200 –.012

=1.188

1.270 –.012

=1.258

1.270 –.012

=1.258

Defective battery

2

69 5 80°F (26.7°C) .000 1.250 – 0

=1.250

1.255 – 0

=1.255

1.230 – 0

=1.230

1.250 – 0

=1.250

Light current

battery

3-additional

charge

38 2 100°F

(37.8°C)+.008

1.200+ .008

=1.208

1.180+ .008

=1.188

1.170+ .008

=1.178

1.180+ .008

=1.188

Discharged

battery-recharge

and

re-inspection

22 4 80°F (26.7°C) .000 1.240 – 0

=1.240

1.245 – 0

=1.245

Buoy

doesn’t float

1.250 – 0

=1.250

Rejected battery

3-replacement

Discharge test

In case no problem is identified after the above inspections, the discharge test should be conducted.

Simulate the operation mode of the vehicle to carry out the discharge test by reducing the battery output

current to voltage 42.0.

Battery and Charger

MERGE 11-13

Chapter 11

The discharge test is the most difficult and time-consuming test. Please use battery discharge tester.

Procedures for discharge test

1. Ensure that the battery is fully charged and that the liquid level of electrolyte in battery compartment

is normal.

2. Connect the tester with the positive ( ) terminal of battery No.1 and the negative terminal of battery

No. 6 (see Fig 11-9).

3. Inspect and take down the temperature of electrolyte of the battery pack. Inspect the second

compartment of each battery (the second one from the positive terminal).

4. Reset the discharger and restart the tester.

5. Sixty minutes after the discharge of the battery, set the discharger at function 3 and measure the

voltage of the battery pack. In the subsequent test, measure the voltage every ten minutes. Measure

with the multimeter the voltages of all batteries when the voltage of the battery pack is higher than

the shutoff point (42.0V) by 5V. Be accurate to 0.01V and measure and take down the voltages of

all batteries.

NOTE: When the shut-off voltage is reached, the tester will shut off automatically.

Fig 11-9: Battery discharge test

Discharge test result presentation

1. In case the discharge time is not less than 60 minutes, the problem is not with battery.

2. In case the discharge time is relatively short (shorter than 60 minutes), the battery should be

replaced with one of 6.7V.

Red probe

connection

(negative electrode)

Black probe connection

(positive electrode)

Battery and Charger

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Chapter 11

Battery voltage

1 2 3 4 5 6Battery condition

7.00V 7.00V 7.00V 7.00V 7.00V 7.00V Very good

7.07V 7.07V 7.22V 6.50V 7.07V 7.07V The service life of batter No 4

is to expire.

7.20V 7.20V 6.67V 7.33V 6.27V 7.33V The service lives of battery No

3 and 5 are to expire.

3. The battery pack of which the discharge time is less than 60 minutes during the discharge test

under 78 (25.6 ) usually cannot sustain a vehicle shift. However, the discharge time is

dependent on the temperature of the electrolyte. The table below shows the discharge time under

different temperatures of the battery pack of which the discharge time exceeds 62 minutes under

80 (26.7 ).

Battery troubleshooting example

Below is the battery troubleshooting example.

Example 1:

Due to the poor performance of the electric vehicle and the battery is suspected to be the cause, the

battery charger is inspected. When the battery is fully charged, the reading on the ammeter of the battery

charger is 8.0A. The charging voltage inspection is conducted and the results are recorded.

Battery number 1 2 3 4 5 6

Charging voltage 10.15V 10.60V 9.80*V 10.16V 10.56V 10.61V

*As battery No. 3, No 1 and No 4 are suspected to have problems, hydrometer inspections are

conducted on all batteries.

Electrolyte temperature

Discharge time when

the shut-off point is

reached

Electrolyte temperature

Discharge time when

the shut-off point is

reached

40-49 (4-9 ) 40 minutes 85-89 (29-32 ) 64 minutes

50-59 (10-15 ) 45 minutes 89-99 (32-37 ) 66 minutes

60-64 (16-18 ) 50 minutes 100-109 (38-43 ) 68 minutes

65-69 (18-21 ) 54 minutes 110-119 (43-48 ) 70 minutes

70-74 (21-23 ) 57 minutes 120-129 (49-54 ) 72 minutes

75-79 (24-26 ) 60 minutes 130-150 (54-66 ) 74 minutes

80-84 (27-29 ) 62 minutes ***** *****

Battery and Charger

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Chapter 11

Hydrometer inspection result:

Battery number Battery compartment

number 1 2 3 4 5 6

Battery 1 (positive terminal) 1.200* 1.265 1.300 1.250 1.280 1.260

Battery 2 1.285 1.275 1.290 1.270 1.295 1.265

Battery 3 (negative terminal) 1.265 1.270 1.275 1.265 1.280 1.275

Battery 4 (negative terminal) 1.275 1.270 1.285 1.265 1.275 1.275

*After the hydrometer inspection, the problem seems to lie with Battery 1. Proceed with the discharge

test.

Discharge test result:

Battery number 1 2 3 4 5 6

Discharge voltage 5.44*V 7.33V 7.73V 7.15V 7.43V 7.41V

*It is apparent that the problem lies with Battery 1 after the 45 minutes discharge test. After further

observation of Battery 4, the battery proves to be normal. Replace Battery 1 with the one that has been

used for the same period of time for the same electric quantity as those in the battery pack.

Battery storage


Please follow the instructions below to store the battery that will not be used for a long time:

1. Keep the battery clean and rust-free. Please refer to “battery maintenance”.

2. In case the battery in the vehicle is stored in winter and is not necessary to be connected with the

charger, the battery of the electric vehicle should be disconnected.

3. Fully charge the battery before storage.

4. Store the battery in shady and cool places. The lower the temperature where the battery is stored is,

the less electricity quantity the battery self discharges. The electric quantity discharged by the

battery stored in 0 (–17.8 ) temperature is very little. The battery stored under 80 (26.7 )

temperature will discharge every few weeks.

5. The 48V E-merge electric vehicle that is not to be used for a long time is preferably to be stored with

the battery connected to the AC compatible battery charger. During the storage, the battery charger

will automatically charge the battery when necessary.

Charge of the battery pack with low electric quantity

Please refer to corresponding maintenance and repair of the battery charger.

Battery and Charger

MERGE 11-16

Chapter 11

Battery charger

Overview

E-merge charger is fully automatic and designed to charge the storage battery of the electric vehicle.

The battery charger can be connected to the vehicle of any mileage, and will continue to charge the

battery as long as it is not disconnected. Insert the receptacle into the vehicle. Before starting it, the

charger has three seconds of time delay.

During the charging, the electronic modules in the charger will sample the voltage of the storage battery.

In case the module detects that the voltage of storage battery is on the rise, it will continue to charge the

battery. In case the module detects that there is no voltage rise, it will conclude that the storage battery is

fully charged and will shut off the charger.

Conditions to be noted before charging

WARNING Electric shock hazard

The vehicle is provided with the on-board charger. Before the operation of the charger, the vehicle must

be driven to and stopped at a platform higher than the ground in such a way to allow the maximum

draught blow and surrounding the charger. In case the charger is used outdoors, rain and sun shields

must be provided (see Fig 11-10). The charger needs a special circuit. For proper circuit protection

method, please refer to the operating instructions of the charger.

The charger can be connected to the AC mains jack all the time. For charging method, please refer to

the descriptive label on the charger. The spring connector must be fully inserted into the on-board

receptacle (see Fig 11-11).

Fig 11-10: Charger protection schematic diagram

Battery and Charger

MERGE 11-17

Chapter 11

Fig 11-11: Electrical outlet

The charger will start automatically a few seconds after the connectors are plugged in. When the storage

battery is fully charged, the charger will automatically stop the charging. Unplug the DC connector to use the

vehicle.

NOTICE

It is a good way to fasten the DC wire on the steering wheel when the battery is charged, which can

work perfectly as a reminder so that the user can store up the wires not to be used after the

charging. Driving over or dragging the wires when the vehicle is in operation will damage the DC

connector.

WARNING

Ungrounded electric installation will be a material hazard for electric shock or electrocution.

The charging (dc) wire is provided with a polarization connector that can be plugged into the on-board electrical

outlet.

Power supply (AC) wire is provided with a grounded connector. Never unplug, cut off or bend the ground

pole.

NOTICE

In case the vehicle is to be charged with a non E-merge charger, please refer to instructions

provided with the charger.

Get to know the charger

The battery charger will respond to abnormal conditions.

1. In case the charger is disconnected with the vehicle during the charge cycle, it will shut off

immediately.

2. In case the AC supply is disconnected, when the power supply is resumed, the charge cycle will

Battery and Charger

MERGE 11-18

Chapter 11

continue till the remaining cycle is completed.

3. In case the storage battery is fully charged in a very short period (less than 2 hours), the charger will

shut off. In case the voltage of open circuit storage battery drops down to a point where the recharge

is needed, the charger will start and charge the battery till it is fully charged.

4. The feature of the charger is that it has an internal timer, which allows at most 16 hours of trickle

charge.

WARNING

To prevent the hazard of electric shock or arc discharge that will result in serious personal injury

or serious damage to the equipment or the charger, before the repair or maintenance procedures,

please see to it to unplug the charger from the AC and DC power supply.

Removal of the charger

WARNING

When the charger is still connected with the power supply, it has lethal voltage when the cover is

removed.

If you suspect your ability to safely perform the following tests, you can ask the trained

electrician/technician to repair the charger.

Please extremely careful not to make the non-insulated part of the testing spike touch any other

parts or the charger frame.

Remove the bolt (1 and 2) on the charger cover and other bolts on the side. Hold the handle on the cover

of the charger and lift up the charger cover. The installation procedures are revere to the removal

procedures. (See Fig 11-12)

Fig 11-12: Start the charger

Battery and Charger

MERGE 11-19

Chapter 11

Maintenance of the battery charger

The only maintenance the charger requires is the periodic cleaning of the auxiliary contacts of AC

connector.

To clean the auxiliary contacts, please press down the elastic connector protective sleeve (See Fig

11-13). Wrap the connector with the emery paper and wipe back and forth for about 10 to 20 times. Keep

the pressure on the cleaned contact surface.

Fig 11-13: Clean the auxiliary contacts of the charger plug

Battery and Charger

MERGE 11-20

Chapter 11

Battery and Charger

MERGE 11-21

Chapter 11

Troubleshooting

The simple and effective way to spot the defective battery charger is to follow the troubleshooting

procedures (see Fig 11-15).

Continuity inspection

WARNING

To carry out continuity inspection, please see to it to disconnect the battery charger from the AC

and DC mains.

To inspect the continuity, please set the DVOM (digital volt/ohm meter) to kilo-ohm and select “continuity”.

The DVOM will send an audible signal when the connection is detected. In case the DVOM has no

connection configuration, then configure the DVOM at kilo-ohm. When the connection is detected, the

DVOM will display “0”. (See Fig 11-14)

Fig 11-14: Continuity inspection

Diode test procedure

To test the diode, first disconnect the AC supply of the battery charger. After setting the DVOM at the

highest usable ohm range, attach the probe to the diode (see Fig 11-16). In case the reading is not the

given one, the diode is broken. It can be replaced as required.

Procedures for component replacement

To replace the parts, install them in the procedures just reverse to the removal procedures. Any

disconnected wire should be given special attention. Please see to it to install them in their

original places.

Battery and Charger

MERGE 11-22

Chapter 11

Charger trouble-shooting procedure

Disconnect AV

wire

Disconnect DC

wire

Start the charger

Inspect the electric

meter for connection

function

Inspect the electric

meter for connection

function

Inspect the diode.

See diode test

procedure

Replace the

diode, and return

to the beginning

Replace the capacitor and return to the beginning

Completion Inspect the

capacitor for smelt

or exterior damage

Replace the

transformer

Start the charger

Inspect the

shunt relay for

good condition

Transformer has

sound

Replace the

transformer, return

to the beginning

Inspect the

connection of

AV wire

Replace PC circuit

board and return to

the beginning

Disconnect DC wire

Start the charger

Inspect the

connection of

DC wire

Repair, replace

elements

Complete, return to

the start

Close sound

of the relay

Start-up begins, and the

charger shuts off; Connect

the DC cable on the vehicle

Plug AC wire

into the

electrical outlet

Electric meter

deflection

Complete the

inspection of the

battery

Transformer

has sound

Disconnect the

AV and DV

wires

Replace PC circuit

board and return to

the beginning

Replace the fuse,

return to the

beginning

Repair or

replace, return to

the beginning

Transformer

has sound

Transformer has

no sound

WARNING

When the charger is connected to the power supply with

housing removed, it has lethal voltage when the cover is

removed. If you suspect your ability to safely perform the

following tests, you can ask the trained

electrician/technician to repair the charger.

Please extremely careful not to make the non-insulated part

of the testing spike touch any other parts or the charger

frame.

NOTE

Attach the test lead to the wires on two sides of the fixed

relay printed circuit board so as to shunt the relay. Plug the

charger into the AC electrical outlet, the transformer may

buzz. This means that the primary coil is in operation, but

the printed circuit board breaks down. In case the

transformer doesn't buzz, the transformer is broken.

Yes

No

Yes

No

Yes

Yes

No

No

No

Yes

Yes

No

Yes

Yes

No Yes

No

Battery and Charger

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Chapter 11

Fig 11-16: diode test procedure

Fig 11-17: lester full automatic controllable silicon charger wiring diagram

Fig 11-15: Charger trouble-shooting procedure

Battery and Charger

MERGE 11-24

Chapter 11

On-board charger

Operating Instructions

1. Always use a grounded outlet. When using an extension cord, avoid excessive voltage drops by

using a grounded 3-wire 12 AWG cord.

2. The charger will automatically turn on and go through a short LED indicator self-test(Models

912-xx0x will flash all LED’s in an up-down sequence and Models 912-xx1x will alternatively flash

its LED RED-GREEN) for two seconds. If the charger is connected to battery pack, a trickle current

will be applied until a minimum voltage is reached. If the charger is used in an off-board application

and the charger is waiting to be plugged into a batter pack, the charging algorithm number will be

displayed for 11 seconds(see “Check/Change Charging Algorithm”) before ultimately displaying an

under-voltage fault(fault disappears when plugged into battery pack).

3. Once a minimum battery voltage is detected, the charger will enter the bulk charging

constant-current stage. Models 912-xx0x will display the current to the battery on the bar graph

and Model 912-xx1x will flash its LED GREEN off more than on to indicate<80% charge status.

The length of charge time will vary by how large and how depleted the battery pack is, the input

voltage (the higher, the better), and ambient temperatures (the lower, the better). If the input AC

voltage is low (below 104VAC), then the charging power will be reduced to avoid high input

currents (Models 912-xx0x ‘AC’ LED and Models 912-xx1x single LED both flash YELLOW). If the

ambient temperature is too high, then the power will also be reduced to maintain a maximum

internal temperature (Models 912-xx0x bar graph flashes and Models 912-xx1x single LED flashes

YELLOW).

4. When the battery is at approximately 80% state of charge, the bulk stage has completed and an >

80% charge indication is given (Models 912-xx0x turn on the ‘80%’ LED and Models 912-xx1x will

flash its LED GREEN on more than off). In the next phase known as the absorption or

constant-voltage phase, the last 20% of charge is then returned to the battery. The charging could

be terminated at this point if the vehicle requires immediate usage, however, it is highly

recommended to wait until 100% charge indication is given to ensure maximum battery capacity

and life.

5. A low current “finish-charge” phase is next applied to return and maintain maximum battery

capacity (Models 912-xx0x will flash the ‘100%’ LED).

6.When Models 912-xx0x “100%” LED or Models 912-xx1x single LED is continuously GREEN, the

batteries are completely charged. The charger may now be unplugged from AC power (always pull on

plug and not cord to reduce risk of damage to the cord). If left plugged in, the charger will automatically

restart a complete chare cycle if the battery pack voltage drops below a minimum voltage or 30 days

has elapsed.

7. If a fault occurred anytime during charging, a fault indication is given by flashing RED with a code

corresponding to the error. There are several possible conditions that generate errors. Some

errors are serious and require human intervention to first resolve the problem and then to reset the

charger by interrupting AC power for at least 15 seconds. Others may be simply transient and will

automatically recover when the fault condition is eliminated. To indicate which error occurred, a

fault indication will flash RED a number of times, pause, and then repeat.

[1 FLASH] Battery Voltage High: auto-recover

[2 FLASH] Battery Voltage Low: auto-recover

[3 FLASH] Charge Timeout : the charge did not complete in the allowed time. This may indicate

Battery and Charger

MERGE 11-25

Chapter 11

a problem with the battery pack (voltage not attaining the required level), or that the

charger output was reduced due to high ambient temperatures.

[4 FLASH] Check Battery: the battery pack could not be trickle charged up to the minimum level

required for the charge to be started. This may indicate that one or more cells in the

battery pack are shorted or damaged.

[5 FLASH] Over-Temperature: auto-recover. Charger has shutdown due to high internal

temperature which typically indicates there is not sufficient airflow for cooling-see

installation instructions 1). Charger will restart and charge to completion if

temperature comes within accepted limits.

[6 FLASH] QuiQ Fault: an internal fault has been detected. If fault 6 is again displayed after

interrupting AC power for at least 15 seconds, the charger must be brought to a

qualified service depot.

Maintenance instructions

1. For flooded lead-acid batteries, regularly check water levels of each battery cell after charging

and add distilled water as required to level specified by battery manufacturer. Follow the

maintenance and safety instructions recommended by the battery manufacturer.

2. Make sure charger connections to battery terminals are tight and clean.

3. Do not expose charger to oil, dirt, mud or to direct heavy water spraying when cleaning vehicle.

Specifications

DC Output-see Operating Instructions

QuiQ Model:912- 48xx

Voltage-nom(v) 48

Voltage-max(v) 67.2

Current-max(A) 18

Battery Type Specific to selected algorithm

Reverse Polarity Electronic protection-auto-reset

Short Circuit Electronic current limit

Ac input

All models

Voltage-max(Vrms) 85—265

Frequency(Hz) 45—65

Current-max(Arms) 12A @ 104VAC(reduced 20%<104)

Current-nominal(Arms) 10A @ 120VAC/5A @ 230VAC

AC Power Factor >0.98 at nominal input current

Battery and Charger

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Chapter 11

Operation

Charger Model:912- Xx0x(10 LED) Xx1x(1 LED)

AC ON Solid YELLOW LED Active

AC Low Flash YELLOW Flash YELLOW

Thermal Cutback Flash Bar graph Flash YELLOW

<80% Charge Indicator - Short Flash GREEN

>80% Charge Indicator Solid YELLOW Long Flash GREEN

100% Charge Indicator Solid GREEN Solid GREEN

Fault Indicator Flash RED Flash RED

DC Ammeter LED Bargraph -

Bat Temp Compensation Automatid Optional

Maintenance Mode Auto-restart if V<2.1Vpc or 30 days elapse

Installation Instructions

WARNING

The output of chargers with greater than 48V may pose an energy and/or shock hazard under

normal use. These units must be installed in the host equipment in such a manner that the

output cable and battery connections are only accessible with the use of a tool by qualified

personnel.

1) Determine Mounting location:

While its sealed nature allows the charger to be mounted virtually anywhere, the choice of

mounting location and orientation is extremely important. For optimum performance and shortest

charge times, mount the charger in an area with adequate ventilation. The charger should also be

mounted in an area that will be relatively free of oil, dirt, mud, or dust since accumulations within

the fins of the charger will reduce their heat-dissipating qualities. Optimal cooling also occurs when

the charger is mounted on a horizontal surface with the fins vertical. More airflow from below the

charger will help cool the fins, so mounting above open areas or areas with cut-outs for airflow is

desirable. Contact Delta-Q for information on other mounting orientations. As the charger may get

hot I operation, the charger must be installed such that risk of contact by people is reduced. The

charger’s AC plug must be located at least 18’’ above the floor/ground surface and the status

display must be visible to the user.

2) Mounting Procedure:

Mount the charger by the mounting plate using appropriate fasteners (i.e.1/4’’ or M6 with locking

hardware).For UL2202 compliance, a 12 AWG green bonding wire with ring terminals must be

attached from the bonding stud located on the front of the charger (identified by) to the vehicle

frame. The vehicle connection must be made using corrosion resistant hardware (e.g., a #

10stainless steel machine screw with at least two threads of engagement and, if required, a paint

piercing washer).

3) DC Battery Connection Procedure:

a) The green wire outputs battery voltage when the charger is not plugged into AC to provide an

interlock function—see fig.1. If used, a user-supplied 1 A fast-blow external fuse must be

installed inline to prevent damage. Shorting or drawing more than 1 A may damage charger and

Battery and Charger

MERGE 11-27

Chapter 11

void the warranty.

b) Securely fasten the black ring terminal from the charger to the negative terminal“.”,

“NEG”,NEGATIVE”) of the battery pack.

c) Check that the correct charge algorithm is being used –refer to section 4).Securely fasten the

red ring terminal to the positive terminal (“+”,“POS”, “POSITIVE”) of the battery pack.

Mechanical

All models

Dimensions 28.0*24.5*11.0cm(11*9.7*4.3)”

Weight <5kg(<11lbs) w/ standard output cord

Environmental Enclosure:IP46

Operating Temperature -30 to +50 (-22 to 122 ), derated

Above 30 ,below 0

Storage Temperature -40 to +70 (-40 to 158 )

AC input connector IEC320/C14(require>=1.8m localized cord)

DC output connector OEM specific w/ 12AWG wire

Regulatory

Safety

EN 60335-1/2-29 Safely of Appliances/Battery Chargers

UL2202 EV Charging System Equipment

UL1564 2nd Edition Industrial Battery Charger

CSA-C22.2 No.107-2 Battery Chargers-Industrial

Emissions

FCC Part 15/ICES 003 Unintentional Radiators Class A

EN 55011 Radio disturbance characteristics(Class A)

EN 61000-3-2 Limits for harmonic current emissions

EN 61000-3-3 Limits of voltage fluctuations and flicker

Immunity

EN 61000-4-2 Electrostatic discharge immunity

EN 61000-4-3 Radiated, radio -frequency, EMF immunity

EN 61000-4-4 Electrical fast transient/burst immunity

EN 61000-4-5 Surge immunity

EN 61000-4-6 Conducted Immunity

EN 61000-4-11 Voltage variations immunity

Battery and Charger

MERGE 11-28

Chapter 11

Figure 1

4) Check/Change Charging Algorithm:

The charger comes pre-loaded with algorithms for batteries as detailed in Table 1. If your specific

battery model is not listed, please contact Delta-Q.

Each time AC power is applied with the battery pack NOT connected, the charger enters an

algorithm select/display mode for approximately 11 second. During this time the current Algorithm

# is indicated on the ‘80%’ LED (Models 912-xx0x) or on the single LED(Models 912-xx1x).A

single digit Algorithm # is indicated by the number of blinks separated by a pause, A two digit

Algorithm # is indicated by the number of blinks for the first digit followed by a short pause. then

the number of blinks for the second digit followed by a longer pause.

To check/change the charging algorithm:

a) Disconnect the charger positive connector from battery pack. Apply AC power and after the

LED test, the Algorithm # will display for 11 seconds.

b) To change algorithm, touch positive connector during the 11 second display period to the

battery pack’s positive terminal for 3 seconds and then remove the Algorithm # will advance

after 3 seconds. Repeat until desired Algorithm # is displayed. A 30 second timeout is

extended for every increment.

Incrementing beyond the last Algorithm moves back to the first Algorithm.

After desired Algorithm # is displayed, touch the charger connector to the battery positive

until the output relay is heard to click (~10 seconds)-algorithm is now in permanent memory.

c) Remove AC power from the charger and reconnect the charger positive connector to the

battery pack. It is highly recommended to check a newly changed algorithm by repeating

step4) above.

Electric Motor

MERGE 12-1

Chapter 12

Overview

The electric vehicle is provided with a 48V DC separately excited reversible traction motor. The

separately excited motor can only be used on the E-merge electric vehicles. TOMBERLIN suggests that

the electric motor that is in a bad state of repair should be sent to the special service store for repair. The

technician who has knowledge and expertise about the service of the electric motor can perform some

simple reparation.

Exterior inspection of the electric motor

Perform the following inspections and tests with the multimeter or circuit breaker without the need to

disassemble the electric motor.

NOTE: Before disconnection, label the wires of the electric motor for easy identification.

Check Procedure 1 internal short circuit

Please refer to Chapter 1 "Safety Protection Measures".

1. Disconnect the battery cable as specified. Please refer to Chapter 1 "Protection for Electrical

Safety".

2. Hold the terminals with two spanners, and disconnect the wire from the connecting terminal of the

electric motor.

3. Attach the black probe of the multimeter set at 200! ohm to the motor enclosure. Scrape

off the paint on the motor cover to ensure good connection. Attach the red probe to the

terminals of A1 A2 F1 and F2 separately (see Fig 12-1). The multimeter shows not-connected. In

case of conducting state, the electric motor should be removed from the electric vehicle and be

repaired by professionals. Please refer to Chapter 9 "Removal of Motor".

3.1 The wrong readings on A1 or A2 terminals may imply three kinds of problems: A1 or A2

grounding, grounding of wires in the electric brush area or armature/commutator grounding.

The wrong reading on F1 or F2 terminals mean F1 or F2 terminal grounding or excitation coil

grounding.

Check Procedure 2 disconnection of armature circuit



Safety".

2. Hold the terminals with two spanners, and disconnect the wire from the A1 and A2 connecting

terminals of the electric motor. Attach the red probe of the multimeter set at 200! ohm to

A1 and the black probe to the A2 terminal. The multimeter should indicate connected. In case

Electric Motor

MERGE 12-2

Chapter 12

of wrong reading, the cause may be the off contact or poor contact of brush set and/or

disconnection of armature winding. The electric motor should be removed from the vehicle and be

repaired by professionals. Please refer to Chapter 9 "Removal of Motor".

Check Procedure 3 open excitation circuit



Safety".

2. Secure the terminals with two spanners, and disconnect wires from connecting terminals F1 and F2

of the electric motor. Attach the red probe ( ) of the multimeter set at 200! ohm to F1 and the

black probe ( ) to F2 terminal. The multimeter should indicate connected. In case of wrong reading,

the cause may be open excitation coil or poor contact of terminal bond. The electric motor should be

removed from the vehicle and be repaired by professionals. Please refer to Chapter 9 "Removal of

Motor".

Fig 12-1: Inspection of the short circuit of electric motor

Electric Motor

MERGE 12-3

Chapter 12

Removal of the electric motor

Remove the electric motor from the electric vehicle. Please refer to Chapter 9 "Removal of

Motor".

1. Before removal, first mark match marks on the end shield of the electric motor and the stator

enclosure, and then secure the electric motor to the pincer pliers with wooden block as shown (see

Fig 12-2).

2. Unscrew the two bolts securing the end shield to the stator enclosure .

3. Unscrew the two screws securing the speed sensor 21 to the end shield enclosure.

4. Remove the armature 17 from the other end of the stator enclosure .

5. Unscrew the two screws 11 securing the brush gear 12 to the end shield (see Fig 12-7).

6. Mark the brush terminals A1 and A2 13 to indicate their positions in the end shield . Then

unscrew the nut , spring washer , small washer and large washer see Fig 12-7). Insert

the terminal into the interior of the stator enclosure through the enclosure wall.

7. Carefully remove the brush set and terminals from the end shield.

8. To remove the brush spring 14 from the gear, pry out the elongation portion of the spring over the

brush carrier. Then remove the spring from the installation buckle (see Fig 12-3).

Fig 12-2: Electric motor components Fig 12-3: Remove the brush spring

Match

mark

Armatur

Electric Motor

MERGE 12-4

Chapter 12

Inspection and test of the motor element

Inspection of the armature

Disassemble the electric motor and carefully inspect the armature for any of the following characteristics:

• The insulating material is charred, carbonized or ruptured;

• The paint coating is abnormally hardened;

• Tip-off;

• The armature winding spreads outwards;

• Armature core iron sheet is damaged;

• The commutator is damaged or burnt;

• The commutator is very dirty or has oil strain;

• The commutator bar bulges up;

• Armature bearing shaft is abraded.

Clean and wipe of the water on the dirty or stained commutator. The abnormal phenomena during

inspection can help spot the cause to the malfunction. The lightly coarse commutator can be polished by

400# or finer emery paper.

WARNING

• It is strictly prohibited to burnish the commutator with abrasive cloth. The grains on abrasive

cloth are conductive, and may result in the short circuit of the commutator bar. It is

prohibited to apply oil or lubricant to the commutator or brush.

NOTE: In case there is oil on the commuttor, the oil seal of the output shaft on the driving axle

may be damaged.

Armature earth test

WARNING

• It is strictly prohibited to immerse the armature into any solvent.

NOTE: Before testing the armature, wipe the armature with a piece of clean cloth. Wipe out

the carbon dust and metal particles between commutator bars.

1. Attach one probe of the multimeter set at 200! ohm to the commutator and the other probe to the

armature core. The multimeter should indicate un-continuity (see Fig 12-4). In case of wrong

reading, the armature should be replaced.

Electric Motor

MERGE 12-5

Chapter 12

Fig 12-4: Armature inspection and test

Fig 12-5: Brush spring elasticity test Fig 12-6: Bearing inspection

Inspection of the excitation winding

The burnout or charring of the insulating material of the excitation winding means the electric motor is

overheated due to the overloaded or grounded or short circuit coil winding. In case the insulating

material of the excitation winding is charred, please replace the electric motor or the stator enclosure

component.

Motor element

1. Inspect the insulator for crack or other damages (see Fig 12-7).

2. Inspect the brush 13 for damage or heavy wear. Replace the brush when necessary.

3. Inspect the brush spring 14 see Fig 12-7). Replace the spring of which the color changes amber

or blue) due to being heated. Replace the spring of which the elasticity is smaller than 16 ounces

(see Fig 12-5).

CommutatoCommutator

core

Electric Motor

MERGE 12-6

Chapter 12

CAUTION

• To inspect the elasticity of the brush spring, it is strictly prohibited to excessively extend the

spring. Excessive force may damage the spring.

NOTE: Once the brush is removed, the replacing one should be mounted. This can ensure that

the connecting terminal and brush be properly aligned in the transmission gear. For the

mounting of brush, please refer to "Assembly of the electric motor".

Once one brush is replaced, all the other brushes should also be replaced at the same time.

Never replace only two of them.

Brushes should be mounted on the same transmission gear, and the two brushes connected

should be symmetrically mounted.

Bearing inspection

1. Wipe off the carbon dust in the bearing with a clean cloth. Inspect the bearing through manual turn

and inspection of the clearance in axial direction A and radial direction (B) (see Fig 12-6).

2. The bearing should be replaced with new one in case the bearing noise is too loud, unable to rotate

smoothly or the clearance is too large. Inspect the bearing, and replace it in case the bearing rusts,

is abraded or cracks or in case the color of the metal of the bearing changes abnormally. Do not

remove the bearing from the armature shaft unless for replacement purpose.

Removal of the bearing

1. Secure the bearing puller to the bearing 15 , and pull the bearing from the armature shaft. Support

the shaft so that it will not fall off when the bearing is removed (see Fig 12-8). Reject the bearing.

Mounting of the bearing

Press the new bearing 15 against the armature see Fig 12-7). Use only the hand arbor press that

exerts pressure on the inside race.

NOTE: Before pressing the bearing to the armature, see to it to secure the large washer 20 to

the armature shaft see Fig 12-7).

The arbor of which the outside diameter is less than 5/8 inch (16mm should be used to press the

bearing to the armature.

Inspection of the speed sensor magnet

Inspect the speed sensor magnet 18 for abrasion or crack. Replace the magnet when necessary see

Fig 12-7).

Electric Motor

MERGE 12-7

Chapter 12

Removal of the speed sensor magnet

Remove the bolts 19 , and take down the speed sensor magnet 18 see Fig 12-7).

Mounting of the speed sensor magnet

Mount the speed sensor magnet 18 to the shaft with bolts 19 , and tighten the torque of the bolts with

22 inch pound 2.5N·m

Readjustment of the electric motor

The electric motor should be readjusted by professional motor maintenance technician. The use of

corresponding activities and procedures is crucial to the success of readjustment to the electric motor.

Electric Motor

MERGE 12-8

Chapter 12

Specifications for the electric motor

Any readjustment must be carried out by professional technicians. The maintenance specifications for

the electric motor are shown in the table below.

Fig 12-7: Electric motor

Electric Motor

MERGE 12-9

Chapter 12

Items Adjustment limits

Commutator diameter min) 2.265inch 66.675mm

Commutator coaxial shaft with armature shaft 0.001inch 0.0254mm

Maximum kerf depth in processing commutator 0.005inch 0.127mm

Oscillation of the commutator bars should not

exceed:0.002inch 0.00508mm

In case the undercut of the commutator segment

insulator is smaller than 0.16 inch 0.406mm , the

undercut should be:

0.031inch 0.8mm

Machined surface of the commutator 8 16microinch 203.2

406.4nm

Resistance of the excitation coil IQ system 3.20hp 1.61! ohm

Assembly of the electric motor

1. In case the bearing is removed, the replacing one should be mounted. Please refer to "Mounting of

the Bearing" in this chapter.

2. Mount the brush.

NOTE: Once the brush is removed, the replaced one should be mounted. This can ensure

that the connecting terminal and brush be properly aligned in the transmission gear. For the

mounting of brush, please refer to "Assembly of the electric motor".

Once one brush is replaced, all the other brushes should also be replaced at the same time.

Never replace only two of them.

Brushes should be mounted on the same transmission gear, and the two brushes connected

should be symmetrically mounted.

2.1. Secure the brush transmission gear a little higher than the top of end shield and make it

face upwards. Insert two terminals through the insulator to the end shield of A1 and A2. Insert

the bolts 11 into the brush transmission gear to the threaded hole of the end shield (see Fig

12-9). Tighten the bolt with a torque of 22 inch pound 2.5N·m).

2.2. Press the elongated portion of the brush back to the original once a time, and push back the

brush till all of them return to the installation grooves. Align the brush spring to one side of the

brush so that the pressure of the spring can hold it in the retraction state (see Fig 12-3).

Electric Motor

MERGE 12-10

Chapter 12

Fig 12-8: Removal of the bearing

2.3. Face the bearing end forward, and put the armature into the stator enclosure. While the

positioning armature ensuring good contact of commutator/brush, the brush should be ensured

to be held. Release the brush, and place the spring outside the brush so that the brush holds

against the commutator.

3. Mount the end shield onto the stator enclosure.

3.1. Align the match marks on the end shield and the stator enclosure before mounting two bolts "8

(see Fig 12-10). Tighten the bolt with a torque of 7.4 foot-pound 10N·m).

4. Ensure the free rotation of the armature. In case the armature cannot rotate freely, remove the

electric motor to spot the problem. In assembly of the electric motor, see to it that the bearing is

properly mounted in the end shield.

Bearing puller

Electric Motor

MERGE 12-11

Chapter 12

Fig 12-9: Mounting of the brush Fig 12-10: Mounting of the end shield

Mounting of the electric motor

1. Clean the input shaft of the driving axle.

1.1. Spray detergent over the input shaft.

1.2. Wipe the input shaft with a piece of clean cloth.

1.3. Inspect the groove of input shaft, and clean the remaining scraps.

1.4. Repeat Step 1.1 to 1.3 until the input shaft is clean.

2. Lubricate the input shaft of the driving axle

2.1. As shown in the figure, extrude about 1/2 inch (1.3cm) of NYE lubricating oil from the tube onto

the putty knife see Fig 12-11).

2.2. Turn the wheel so as to rotate the input shaft.

2.3. Evenly apply the motor coupling grease onto the rotating input shaft. Start the application from

the position 1/8 inch (3.1mm) lower than the shaft end to the driving axle (far end of the shaft)

(see Fig 12-12).

2.4. The grease should be evenly applied in the groove, and the width should be about 3/8 inch

(9.5mm).

2.5. Erase the grease in one groove with a flat-head screwdriver so that air can be vented when the

electric motor is put to the input shaft.

Terminal contacts

Electric Motor

MERGE 12-12

Chapter 12

Fig 12-11: Apply grease onto putty knife Fig 12-12: Apply grease into input shaft grooves

2.6. Inspect the chamfer and end of the input shaft to ensure that areas shown in the figure are free

of grease (see Fig 12-14).

3. Mount the buffer.

3.1. Mount the buffer "28 into the motor coupling see Fig 12-7).

NOTE: The motor coupling must be free of grease or scrap.

3.2. Ensure that the mounted buffer is situated at the bottom of the coupling.

4. Mount the electric motor on the driving axle.

4.1. Fit the motor coupling over the input shaft of the driving axle.

NOTE: The coupling will squeeze redundant grease on the input shaft towards the driving

axle. When the electric motor is fitted over the input shaft, the clearance between the electric

motor and the driving axle enclosure is about 1/16 inch (1.6mm) see Fig 12-14).

4.2. Mount the six bolts and washers of the fixed electric motor on the driving axle. Do not tighten

them.

4.3. Tighten the bolts with hand (1 and 2) in the order shown in the figure (see Fig 12-15).

Continue to tighten the bolts with hand until the electric motor is secured to the driving axle

enclosure.

! NOTE:

Ensure the electric motor is correspondingly secured to the enclosure of the driving axle

Failure to mount in the right order and screw down the mounting bolt of the electric motor with a

certain torque will result in the motor noise during operation.

GreaseInch

1/8Inch3/8Inch (9.5MM)

Electric Motor

MERGE 12-13

Chapter 12

Fig 12-13: Clean the chamfer and input shaft end Fig 12-14: Clearance of electric motor and driving axle

4.4. Tighten the bolts , , , and in turn with a torque of 6.3 foot-pound 9N·m). see

Fig 12-15

4.5. Install the electric motor wires. Ensure that they are connected with the right terminals of the

electric motor and that the terminals orientation are right. Please refer to the wiring diagram on

page 9-7. Tighten the clamp nuts of the terminal with a torque of 7.5 foot-pound 10.2N·m).

4.6. Fasten the armature wire and electric excitation wire with binding tape so as to prevent the

electric motor wire from contact with the electric motor or the driving axle when the electric

vehicle is in operation.

4.7. Connect 3-wire speed sensor wires and electric vehicle harness.

5. In case the wheels are removed, mount them and tighten the wheel nuts with fingers.

6. Turn the TOW/RUN switch to the TOW position. To connect the battery, first connect the positive

electrode cable then tighten it with a torque of 110 inch pound 12.4N·m). Apply the antirust

oil on all connecting terminals to minimize future corrosion.

7. Set the Tow/Run switch at the RUN position.

8. Inspect the electric vehicle for normal operation.

• Ensure the electric vehicle is moving forward when the Forward/Reverse switch is at FORWARD

position.

• Ensure the electric vehicle is moving backward when the Forward/Reverse switch is at REVERSE

position. When the Forward/Reverse switch is at REVERSE position, the backing-up buzzer

should give off an audible alarm.

9. Ensure the electric vehicle is not moving when the Forward/Reverse switch is at NEUTRAL

position.

Chamfer

Shaft end

1/16inch 1.6MM

Electric Motor

MERGE 12-14

Chapter 12

Speed sensor of the electric motor

Inspection of the speed sensor of the electric motor

Please refer to Chapter 10 "Check Procedure 9"

Fig 12-15: Electric motor frame

Removal of the speed sensor

1, Disconnect the battery cable as specified. Please refer to Chapter 1 "Protection for Electrical

Safety".

2. Unplug the three-wire connector 22 from the hardness of the electric vehicle (see Fig 12-16).

3. Take down the speed sensor 21 of the electric motor from the end shield of the electric motor with

a screwdriver.

4. Remove the speed sensor magnet 18 from the armature end with a spanner.

Mounting of the speed sensor of electric motor

1. Mount the speed sensor magnet, and tighten the bolts with a torque of 110 inch pound 12.4N·m)

(see Fig 12-16).

2. As shown in the figure, align the speed sensor 21 and secure it with the screwdriver.

3. Plug the three-wire connector 22 onto the harness of the electric vehicle.

Electric Motor

MERGE 12-15

Chapter 12

4. Turn the TOW/RUN switch to the TOW position. To connect the battery, first connect the positive

electrode cable then tighten it with a torque of 110 inch pound 12.4N·m). Apply the antirust

oil on all connecting terminals to minimize future corrosion.

Fig 12-16: E-merge electric motor speed sensor

TOMBERLIN AUTOMOTIVE GROUP, INC.3123 WASHINGTON ROAD

AUGUSTA, GA 30907

WWW.TOMBERLIN.NET(706) 860-8880

Documents

2010 Emerge Service Manual